LPG Plant Fire Protection Design

LPG Blending facilities – List of documents for Tender

1, Scope of work

8122-03-DA-001

2, Sub vendor list

8122-03-DA-001 VL, 8122-01-DA-001 VL

3, Engg Specifications 25ES205/94-r1 8122-03-ES-001 8122-12-DA-001 8122-12-DA-002 25ES201 25ES202 02ES042/97 02ES023/97 8122-01-PS-002DV

Fabrication and Erection of steel piping Spec for GRP piping Spec for Cement Mortar lining Spec for Pipeline concrete coating Erection of Static equipments Erection of Machinery items Spec for Cold Insulation Spec for Painting Standard Spec for Deluge Valves

4, Data Sheets of Fire equipments 8122-01-DA-FH100 Hydrant assembly 8122-01-DA-FH101 Water Monitor 8122-01-DA-FH102 Spray nozzles 8122-01-DA-FH103 Hose box 8122-01-DA-FH104 Deluge valve system 5, Layouts 8122-03-OP-00001 8122-03-UP-00001 8122-03-UP-00002 8122-03-UP-00003 8122-03-KP-00001 8122-03-KP-00002 8122-03-KP-00003 8122-03-KP-00004 8122-03-KP-00005 8122-03-KP-00006 8122-01-ZM-00001

Overall plot plan Unit plot plan – Coastal terminal area Unit plot plan – Heat Exchanger area Unit plot plan – Sea Water Pump house Piping Key plan Piping Key plan Piping Key plan Piping Key plan Piping Key plan Piping Key plan Piping routing of Fire hydrant

6, Isometrics 8122-03-IS-001 to 016 Piping Isometric drawings 16 Nos 7, Schedule of Items of work 8122-03-SW-001

8122 – 03 – DA – 001R0 Page 1 of 6

PIPING DEPARTEMNT

Supply, Fabrication, Erection, Testing and Commissioning of Piping and Equipments

Introduction M/s Hindustan Petroleum Corporation Ltd (HPCL) proposes to install an ‘Online Blending Facility’ at their Mangalore terminal for blending of Propane and Butane unloaded from the ship. For this purpose they have requested additional area (appr 3 acres) adjacent to their Coastal terminal which is 1 km away from the NMPT jetty. The Online Blending facility shall include one LPG Heater, 3 nos Sea water pumps, one Static Mixer, 2 nos LPG Booster pumps and connected piping and instruments. The LPG Booster pumps will be located in the new Pump house being constructed at HPCL Terminal whereas all other equipments will be located in the NMPT jetty area. The Sea water pumps shall be located in the existing fire water pump house after relocating the existing Jockey pumps. This tender specification covers the fabrication, erection, testing and commissioning of the LTCS and CS piping systems and supply, fabrication, erection, testing and commissioning of the GI & GRP piping systems, supply and erection of Fire fighting equipments and Erection of Equipments The major piping systems in the plant are 1, LPG system – Carbon steel, Class 300 2, Propane, Butane system – Low Temp Carbon steel, Class 300 3, Sea water system – Glass reinforced plastic (GRP), Class 150 4, Fire water system – Cement lined Carbon steel, Class 150 & Galvanised Iron, Class 150 A, Scope of work - Piping The scope of the Contractor includes 1, Fabrication and Erection of CS & LTCS piping 2, Supply, fabrication and erection of GI & GRP piping 3, Fabrication and Erection of Cement lined CS piping 4, Testing & commissioning 5, Supply/Application of Painting 6, Supply/Installation of Cold Insulation 7, Dismantling of existing piping PRPD. BY : GSP

CHKD. BY : KPM

APPRD. BY: KAK

ISSUED ON: 16-10-2009

FACT ENGINEERING AND DESIGN ORGANISATION

PIPING DEPARTEMNT

8122-03-DA-002R0

Fabrication and Erection of Piping

Page 2 of 6

8, Tie in connections with the existing systems 9, Supply/erection of Structural supports etc 10, Supply and Erection of Fire fighting equipments The details of the above are given below 1

Fabrication and Erection of CS and LTCS piping

The Fabrication and Erection of piping shall be done strictly as per drawings, codes, standards, Engg specification 25ES205 – 94/R1( Fabrication and Erection of Steel piping) and instructions from the Engineer in charge in a professional way. All the tools, tackles, consumables, manpower etc, required for the work, shall be arranged by the Contractor. The following codes/standards shall apply a, ASME B31.3 – Process piping b, OISD 144 – LPG Installations c, OISD 158 – Recommended Practices on Storage and handling of Bulk LPG d, OISD 214 – Cross country LPG pipelines 2

Supply, fabrication and erection of GI & GRP piping

GI & GRP materials including pipes, fittings, flanges, gaskets, fasteners, CI/Bronze valves etc are included in the scope of the Contractor. These items shall be procured from the Sub Vendor list attached to the tender. If any item is required for which vendor list is not given, the Contractor shall get prior approval from the Owner/ Consultant before procuring the item. The general specification of the GRP items ( 8122-ES – 03 – 001) is attached. The Contractor shall forward their procurement data sheets/specifications to Owner/Consultant for their review All transportation, loading/unloading, handling, follow up with the supplier etc are included in the scope. The items shall be despatched from the supplier’s works only after inspection by Owner/ Consultant or after getting clearance from them. For all items procured by the Contractor, 6 copies of Manufacturer’s Test Certificates for all mandatory tests shall be furnished by the Contractor.

FACT ENGINEERING AND DESIGN ORGANISATION

PIPING DEPARTEMNT

8122-03-DA-002R0

Fabrication and Erection of Piping

The Fabrication and Erection of piping shall be done

Page 3 of 6

strictly as per drawings, codes,

specifications/standards and instructions from the Engineer in charge in a professional way. The installation of GRP piping shall be as per AWWA Manual M45 – Fibreglass pipe Design. All the tools, tackles, consumables, manpower etc, required for the work, shall be arranged by the Contractor. The required gaskets and fasteners (galvanized) shall be supplied by the contractor although there are no separate rates for theses items. Branch connections shall also be made by the Contractor at no extra cost. For GI piping, all the threaded joints shall be seal welded after hydro static pressure testing. 3

Fabrication and Erection of Cement lined piping The existing cement lined Fire water headers are to be re routed as per drawing. Also the Jockey

pump discharge lines are to be hooked up with the existing Fire water header in the pump house. Necessary sleeves for joining, fasteners ( Galvanised)/non metallic gaskets, cement, sand, steel etc for cement lining are in the scope of the Contractor. Cement lining of new piping as well as repair of cement lining of the existing piping (if any) as per Specification 8122-12-Da-001attached shall also be carried out by the contractor at the quoted rate. 4

Testing and Commissioning

Necessary Tests and Inspection of the piping during fabrication/erection and after erection shall be carried

out by the Contractor.

Radiographic/ Ultrasonic Inspection of 100% butt joints and DP testing of 100% fillet joints shall be arranged by the Contractor. After completion of the fabrication and erection, the piping shall be subjected to Hydrostatic pressure Testing at 1.5 times the design pressure. All the tools, tackles, consumables, manpower etc, required for the work, shall be arranged by the Contractor 5

Supply and Application of Painting

All Carbon steel and LTCS piping shall be coated with 1coat of primer and Structurals shall be coated with 2 coats of primer and 2 coats of finish paint as per Engg specification 02ES203/97. All materials,

FACT ENGINEERING AND DESIGN ORGANISATION

PIPING DEPARTEMNT

8122-03-DA-002R0

Fabrication and Erection of Piping

Page 4 of 6

tools/tackles, manpower, scaffolding etc shall be arranged by the Contractor. Sand/shot Blasting is not envisaged. The primer shall be of ‘Two pack poly urethane holding primer’ ( 30 microns DFT) and the finish coats shall be of ‘High build poly urethane coating’ ( 60 microns total DFT). 6

Supply and Installation of Cold Insulation as per 02ES042/97

Pre formed Poly urethane Cold Insulation over the pipes/valves/flange joints etc shall be applied as per drawings/specifications /standards and instructions from the Engineer in charge. For all items, 6 copies of Manufacturer’s Test Certificates shall be furnished to HPCL. All materials, tools/tackles, manpower, scaffolding etc shall be arranged by the Contractor. The supply and installation of Permali blocks( treated teak wood blocks)/ High Density Poly Urethane blocks at the location of supports is also in the scope of Contractor. Providing 12 mm concrete coating over the insulated piping as per Specification 8122-12-DA-002 attached is also in the scope of the Contractor. 7

Dismantling of existing piping

For the hook up/ installation of new piping, some of the existing pipelines including fittings, valves, flanges etc are to be dismantled. The dismantled piping is to be transported to the location specified by the Owner 8

Tie in connections with the existing system Necessary tie in connections for hooking up the new system with the existing system shall be carried

out by the Contractor. Draining, flushing, blinding, cold cutting, dismantling / boxing up of joints, temporary connections and any other activity required for obtaining hot work permit are to be carried out by the Contractor. Hook up at Loading arm area is with flange and no payment shall be made for this tie in connection. (Payment shall be made for Fabrication and Erection only).

FACT ENGINEERING AND DESIGN ORGANISATION

PIPING DEPARTEMNT

9

8122-03-DA-002R0

Fabrication and Erection of Piping

Page 5 of 6

Structural supports etc

Necessary pipe supports shall be done by the Contractor. The structurals shall also be painted as per specification. Supply of structurals and MS plates is also included in the Contractor’s scope. All miscellaneous works required for the completion of the job are in the scope of the Contractor. 10 Supply and Erection of Fire Fighting Equipments Supply and erection of Fire fighting equipments such as Deluge valves, Monitors, hydrants, Spray nozzles, quartzoid bulbs etc are included in the Scope of Contractor including gaskets, fasteners etc. Supply of these items shall be as per specification 8122-01-PS-002DV and Data sheets ( 8122-01-DAFH100, FH101, FH102 , FH103& FH 104) attached. 11

Free issue of Materials

The following materials, limited to the extent of actual usage, shall be issued to the Contractor free of cost Metallic pipes, fittings, flanges, gaskets/fasteners( only for CS/LTCS piping) Valves ( except CI/ Bronze valves), Strainers, Static Mixer 12

Drawings Construction issue isometric drawings shall be issued except for Fire water piping and for small

bore lines below 50NB. The quantities indicated are approximate only. Contractor has to supply and erect as per actual requirement. B 1,

Scope of work – Equipments The following equipments are to be erected as per Engg specifications 25ES201 and 25ES202

1, LPG Booster Pump - Vertical, 2 Nos, 4Te weight, 1.2M x 1.2 Mx 5.5M appr. dimensions 2, Sea water pump – Vertical, 3 Nos, 2.75Te weight, 1.5M x 1.5M x 12 m appr dimensions 3, Jockey pump – Vertical, 2 Nos, 1Te weight, 1.2M x 1.2M x 12 M appr dimesions 4, LPG Heater – Horizontal, 1 No, 10.5 Te weight, 953mm dia x 8300mm overall length

FACT ENGINEERING AND DESIGN ORGANISATION

PIPING DEPARTEMNT

2

8122-03-DA-002R0

Fabrication and Erection of Piping

Page 6 of 6

All equipment shall be erected as per the instructions specified in the Instruction Manual supplied by equipment vendor. If suppliers’ engineers are available at site, erection of equipment shall be as per their instructions.

3

Before taking over the foundation for erection, its dimensions, co-ordinates, orientation and elevations shall be checked with relevant layout drawings. Location and size of the foundation pockets shall also be checked. Serious deviations, if any, shall be reported to HPCL engineers at site.

4,

Foundation surface may have to be dressed with a chisel to remove irregularities or to ensure sufficient roughness. This shall be done by the erection contractor.

5,

Before placing the equipment over foundation, the foundation shall be washed clean.

6,

The equipment shall be thoroughly cleaned by compressed air or clothes to remove dust/dirt.

7

Foundation bolts are supplied along with the equipment. Erection contractor shall check whether correct foundation bolts as per equipment drawings are supplied.

8

In case foundation bolts are not available with the equipment, bidder shall supply the same. Unit rate (Per Kg basis) shall be quoted in the bid for supply of various sizes of foundation bolts.

9

Equipment and drivers shall be aligned at site by erection contractor. If the couplings are supplied with pilot bores, boring of the couplings to suit shaft diameters and cutting keyways shall be done by erection contractor. In case any error in holes on base plates are noted, this shall be got rectified by the erection contractor. Filling lubricants shall be done by erection contractor. Lubricants will be supplied by HPCL.

10

Shims, wedges, jack bolt pads, routing materials etc. required for erection shall be supplied by erection contractor. Shims shall be of SS 304 material.

11

Leveling of equipment shall be done by precision tools.

12

All tools, tackles, labour and consumables for erection shall be supplied by the erection contractor. Bidders shall visit the site and familiarize the site conditions before quoting.

FACT ENGINEERING AND DESIGN ORGANISATION

TECHNICAL PROCUREMENT SPECIFICATION

8122 - 03 - DA - 001 VL SUB VENDOR LIST - Piping PAGE 1 OF 2 R 0

A)

GRP PIPES & FITTI GS

1. 2. 3. 4. 5. 6. B)

M/s Shriram SEPL Composites, Chennai M/s Amiantit, Goa M/s Marketing Services Consortium, Coimbatore M/s Sunrise Polymers & Industries, Vadodara M/s Sangir Plastics P.Ltd., Mumbai. M/s Balaji Fibre Reinforce, Vadodara BRO ZE & CI VALVES

1. 2. 3. 4. 5. C)

M/s Leader valves, Jallunder M/s Brightech Valves, Ahmedabad M/s Steel strong, Mumbai M/s Flowsteer, Ahmedabad M/s Easwar Engg, Chennai METALLIC GASKETS

1. 2. 3. 4. 5. 6.

00FT024/94

D)

M/s IGP Engineers, Chennai M/s Mechanical Packing Industries, Mumbai M/s Spiraseal Gaskets, Chennai M/s Gaskets India, Mumbai M/s Unique, Mumbai M/s Vicap, Chennai

BOLTS & UTS

1. 2. 3. 4. 5. 6. 7. 8.

M/s Echjay Industries, Mumbai M/s Fasteners & Allied Products, Hubli M/s Fasteners India Manufacturers, Mumbai M/s Hardwin Fasteners, Mumbai M/s Nagabhushanam Industries, Bangalore M/s Pacific Forgings, Mumbai M/s Vaibhav Industries, Mumbai M/s Fix fit Fasteners, Kolkota

0

15.10.09

REV.NO.

DATE

FOR TENDER DESCRIPTION

GSP

KPM

KAK

PREPARED

CHECKED

APPROVED

FACT ENGINEERING AND DESIGN ORGANISATION

TECHNICAL PROCUREMENT SPECIFICATION

8122 - 03 - DA - 001 VL SUB VENDOR LIST PAGE 2 OF 2 R 0

E)

GI Pipes 1. 2. 3. 4. 5. 6.

00FT024/94

F)

M/s Ajanta Tubes, New Delhi M/s CSK Tube Enterprise, Chennai M/s Jindal, Mumbai M/s Surya Tubes, New Delhi M/s Sri Laxmi Metal Udyog, Bangalore M/s Ridhi Steel& Tubes, Ahmedabad GI & CS fittings& flanges

1. 2. 3. 4. 5. 6.

M/s Madras Engg works, Mumbai M/s Teekay Tubes, Mumbai M/s Metal Forge, Mumbai M/s Super Forge, Mumabi M/s Tube Products, Baroda M/s Evergreen Hardwares, Bangalore

0

15.10.09

REV.NO.

DATE

FOR TENDER DESCRIPTION

GSP

KPM

KAK

PREPARED

CHECKED

APPROVED

FACT ENGINEERING AND DESIGN ORGANISATION

TECHNICAL PROCUREMENT SPECIFICATION 1

8122-01-DA 001 VL

SUB VENDOR LIST - Fire Fighting

PAGE

1

OF 1 R 0

Fire Hydrant a. Zenith Fire Services b. HD Fire Protect Company c. New Age Industries 7.0 Saha Bhogilal & Jethlal Bros

2

Medium Velocity Water Spray Nozzles a. HD Fire Protect Company b. New Age Industries c. Zenith Fire Services d. Saha Bhogilal & Jethlal Bros e. Kidde

3

Stand post type water monitors. a. Zenith Fire Services b. HD Fire Protect Company c. New Age Industries d. Deepak Safety Systems

Note: For bought out items from vendors ,other than that indicated in Subvendor list , prior approval from Purchaser shall be obtained.

0

16.11.09

First issue

REV NO

DATE

DESCRIPTION

KK

CRP

PREPARED

FACT ENGINEERING AND DESIGN ORGANISATION

CHECKED

JK

APPROVED

iso2.sty

ENGINEERING SPECIFICATION

FABRICATION & ERECTION OF STEEL PIPING CONTENTS

1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 6.0.0

GENERAL FABRICATION WELDING HEAT TREATMENT THREADED AND FLANGED JOINTS PROTECTION & SIZE OF PREFABRICATED PIPE SPOOLS 7.0.0 INSTALLATION OF PIPE SUPPORTS 8.0.0 PIPING INSTALLATION 9.0.0 TESTING AND INSPECTION 10.0.0 PRESSURE TEST AND OTHERS 11.0.0 APPENDICES

——————————1.0.0

GENERAL

1.1.0 1.1.1

SCOPE This specification covers the general requirements for fabrication and installation of steel piping (including carbon steels, low-alloy steels, and stainless steels) within petroleum refineries and chemical plants. When conflict occurs between this specification and the piping drawings or the individual specification, the order of precedence shall be piping drawings, individual specification, and this specification. REFERENCES The requirements contained in the latest editions of the following standards shall form a part of this specification, in the manner and to the extent indicated herein: 1. Indian Boiler Regulation (IBR) 2. ANSI B2.1, Pipe Threads 3. ANSI / ASME B31.3, Chemical Plant and Petroleum Refinery Piping 4. ASME, Boiler and Pressure Vessel Code: Section V- Non-destructive Examination, Se c t i o n VI I I - D i v i s i o n 1 , U W- 5 1 Radiographic Examination of Welded Joint, Section IX- Welding and Brazing Qualifications. DEVIATIONS When piping cannot be fabricated and installed as shown on the piping drawings, or when it is deemed to be more appropriate to fabricate and to install the piping in a manner other than as shown on the drawings, the FEDO Engineer / Representative shall be consulted and the piping shall be fabricated and installed in accordance with his instructions.

1.1.2

1.2.0 1.2.1

1.3.0 1.3.1

2.0.0

FABRICATION

2.1.0 2.1.1

MATERIAL CONTROL Packages of piping materials delivered to the jobsite shall be opened immediately, and the quantities, specifications, sizes, and identifica-

PRPD. BY:

CHKD. BY:

2.1.2

2.1.3

2.1.4

2.1.5

2.1.6

2.1.7 2.2.0 2.2.1

2.2.2

2.2.3

2.3.0 2.3.1

23.2

2.3.3

25ES205 / 94 - R1 PAGE 1 OF 28

tion ( color identification and die stamp ) shall be checked and recorded in the material ledger. The materials shall be stored promptly and neatly in the designated warehouse or storage yard. When the identification is inadequate, the material shall be marked according to the colour identification or an identification mark such as die stamp shall be applied before storing the material. Piping materials shall be issued only upon presentation of Material Issue Slips signed by the FEDO Engineer / Representaive. Piping materials shall be issued only against the relevant isometrics. Issued materials shall be indicated on the drawings or material use charts, etc., to prevent duplication of issues. Any surplus materials found on the job - site shall be returned promptly to the warehouse or storage yard. When more material is needed as a result of faulty fabrication or other similar reasons, the FEDO engineer shall promptly be in formed of the matter so that he can give further directions and advice. Special precautions shall be taken to keep electrodes and gaskets dry during storage. PRECAUTIONS FOR PREPARATI ON & FABRICATION When the location of piping connections by field welding is not shown on the piping drawings, consideration shall be given to preparation and fabrication of piping materials so that the field welding position is flat or horizontal as far as possible. The minimum clearance between the edges of two adjacent welds shall exceed 25mm or 4 t imes the pipe n ominal wall t hickness, whichever is greater. When both welded pipes and piping components having a longitudi nal welded joint are joined at the end, in the girth butt welds the dimension between the longitudinal welded joints shall exceed 5 times the nominal pipe wall thickness of the thicker of those being joined. In unavoidable circumstances when the dimension is less than 5 times, both longitudinal welded joints in the girth butt welds shall be examined by radiography over 100mm. In addition, Section 8.1 (14) shall be considered in the preparation and fabrication. CUTTING Pipes shall be marked accurately and then cut according to the dimensions shown in the piping drawing or the dimensions most suitable for the conditions of field installation. When irregular cutting is required for single and multiple branch connections and for curved and mitred segments of pipe, the cutting shall be performed by using a template. In principle, pipes shall be cut mechanically with a pipe cutter or a high speed cutter. When cutting ss pipe using a high speed cutter, an

APPRD. BY:

FACT ENGINEERING AND DESIGN ORGANISATION

ISSUED ON: 19 - 8 - 96

ENGINEERING SPECIFICATION

2.3.4

2.4.0 2.4.1

2.4.2

2.4.3

2.4.4

FABRICATION & ERECTION OF STEEL PIPING

abrasive wheel for stainless steel shall be used. When pipe is of a large diameter, or when a pipe cutter or a high speed cutter cannot be used the following methods may be used. a) Carbon Steel Carbon steel pipe may be cut with automatic or manual oxygen- acetylene gas apparatus. However, base metal with a carbon content of more than 0.35% shall not be cut with oxygen-acetylene gas apparatus. b) Low-alloy steel pipe Only when unavoidable, low-alloy steel pipe may be cut with oxygen-acetylene gas apparatus pursuant to Subitem (a) above. c) Stainless steel pipe Only when unavoidable, stainless steel pipe may be cut by plasma arc cutting or arc air gouging. In this case, the pipe shall be coated with spatter deposit prevention paint to avoid adhesion of spatter. END PREPARATION Shape of Grooves 1. In principle, grooves for butt welding ends shall be shaped in accordance with ANSI B16.25 However, the grooves shall be in accordence with the approved Procedure Qalification Records(PQR). 2. Unless otherwise specified, the grooves shall be in accordance with the requirements shown in Table below which conform to ANSI B16.25. PIPE WALL THICKNESS (t)

GROOVE

3 mm or less (stainless steel) and 4mm or less (carbon steel and low alloy steel)

Square groove or slightly bevelled

Over 4mm (but over 3mm for stainless steel ) to 22mm

Single v groove asper figure 1a

Over 22 mm

Double v groove as per figure 1b

Shape of Internal Trimming and Misalignment 1. Radial misalignment at the joining ends of piping components shall be such that full penetration can be attained. 2. Where component ends have an internal misalignment over 1.6mm, the thicker component with the wall extending internally shall be trimmed internally to an angle less than 300C as shown in Figure2. However, such trimming shall not result in a finished wall thickness less than the required minimum design thickness plus corrosion and erosion allowances. End Preparation method In principle, the end preparation shall be performed by machine. However, when the preparation is other than by machine, any cracks, flaws, burrs or oxidation scale (rust) shall be removed from the surface with a grinder. Treatment after End Preparation

2.5.0 2.5.1

2.6.0 2.6.1

2.6.2

25ES205 / 94 - R1 PAGE 2 OF 28

When carbon or low-alloy steel pipes and piping components with the ends prepared are to be stored for an extended period, a groove face rust preventive that will not damage the welding shall be applied to the ends (Appendix I). The rust preventive shall be removed prior to welding, as far as possible. BENDING In principle, ready-made elbows shall be used for bends of piping. However, when bends of a large radius are required due to fluid characteristics or plant performance, the pipe may be bent to shape.The procedure for bending shall be as follows: 1. In principle, pipe shall be cold bent with a pipe bender. However, when the pipe bender cannot be used because of the large pipe diameter, the pipe may be bent by heating or by high frequency induction.Lowalloy and stainless steel pipes shall not be bent by heating. 2. Pipe bends shall be made of one piece of pipe with no welds at the bend. 3 The pipe shall be smooth on both the exterior and interior, and shall be bent so as not to form any cuts, cracks, wrinkles, dents, etc. 4 Flattening of a bend shall not exceed the requirements shown in Section 2.8 figure 6. 5 The minimum bending radius shall be greater than 1.5 times the nominal diameter of pipe, unless otherwise specified on the piping drawings or the individual specification. 6 Low-alloy and stainless steel pipe shall be heat treated in accordance with the individual specification to relieve residual stress and work hardening of the bend. However, the heat treatment may not be applied to austenitic stainless pipe or to nickel-alloy steel pipe. 7. For carbon steelpipe of 25 NB and smaller, steam tracing, or discharge-end piping of vents, drains, etc., the pipe may be bent to the required angle by heating with an oxygen-acetylene gas torch. However, precautions shall be taken to prevent damage to the pipe by overheating and to ensure that the roundness of the steel pipe is maintained. MITRE BENDS Unless otherwise specified, mitre bends shall be used for piping 350NB and larger. For piping of 300 NB and smaller, ready-made smooth elbows shall be used. Mitre bends shall be fabricated as follows unless otherwise stated in the piping drawings or the individual drawings. 1 Mitre bends to be used at bends greater than 450C shall consist of not less than three segments. The minimum distance (l) between alternate segments of the mitre bend shall be 4 times the pipe nominal wall thickness or 25mm, whichever is greater (Figure3)

FACT ENGINEERING AND DESIGN ORGANISATION

25 ES205 / 94 - R1

FABRICATION & ERECTION OF STEEL PIPING

PAGE 3 OF 28

FIGURE 1 B

FIGURE 1 A

WHEN t > 22 mm

WHEN t - 4mm to 22 mm

33 1/2° ± 2 1/2°

R 3.2mm 37° ± 2.5° 19

t

10°± 1°

1.6 ± 0.8

t

ENGINEERING SPECIFICATION

1.6 ± 0.8 3.2 ± 0.8

3.2 ± 0.8

FIGURE 2 TRIMMING AND PERMITTED MISALIGNMENT

OVER 1.6 mm

THIS PORTION SHALL BE FINISHED

SMOOTHLY SO AS NOT TO HAVE A SHARP EDGE, WHICH MAY HINDER RADIOGRAPHIC EXAMINATION

30° MAX

FIGURE 3 SHAPES OF MITRE BENDS 15°

30°

1.5 D

30°

1.5 D

FIGURE 4 ANGLE OF MITRE BENDS

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION 2 3

4

FABRICATION & ERECTION OF STEEL PIPING

The radius of the mitre bend shall be greater than the nominal diameter of the pipe. The maximum mitre angle (ß of Figure 4) of each segment shall be as follows: When design pressure is 8kgf / cm2G or less

: β ≤ 22030’

2.7.7

When design pressure is 28 kgf / cm2 G or less

: β ≤ 15000’

2.7.8

When design pressure exceeds 28 kgf / cm2G

: β ≤ 11 015’

The segments shall be neatly cut so that they will closely fit with each other when assembled. Cutting and end preparation of pipe shall be in accordance with the requirements (Sections 2.3 and 2.4) 5 When designing the shape of a groove, the mitre angle shall be considered and the shape of the groove shall be suitable for the welding process used. 6 When assembling the mitre bend, the segments shall be laid out and tack welded on a surface plate or other flat surface to keep the centers of the segments aligned. 7 After welding is completed, the interior of the pipe shall be inspected and any internal weld protrusions shall be removed. 8 Welding and heat treatment shall be performed in accordance with the requirements specified in Sections 3.0.0 and 4.0.0 of this specification. 2.7.0. BRANCH CONNECTIONS 2.7.1 Branch connections shall be fabricated by assembling the fittings that have dimensions and configurations shown in the piping drawings.Unless otherwise specified, branch connections shall be made in accordance with Figure 5 and as follows: 2.7.2 Branch connections, which are made by providing a hole in the main run pipe and inserting a branch pipe or a coupling, shall be as follows: a The hole provided in the main run pipe shall conform to the requirements of Section 6. b When the main run pipe is welded pipe, the welds of branch connections shall be made so as to avoid the welds of the main run pipe. 2.7.3 Branch connections shall be made by means of fully penetrated groove welds. The groove welds shall be made in accordance with the same welding procedure as for girth butt welds. 2.7.4 In no case shall scraps of metal resulting from making the hole be left inside the pipe. 2.7.5 When making branch connections, a jig or a metal fitting shall be attached to the main run pipe to prevent distortion of the main run pipe or bending of the branch pipe due to welding. The material of the metal fitting shall be similar to the main run pipe. 2.7.5 If reinforcement pads are used, unless otherwise specified, a 3.0mm dia vent hole shall be provided (at the side and not at the crotch) in the reinforcement pad to reveal leakage in the weld

2.8.0 2.8.1

2.8.2

2.9.0 2.9.1

25ES205 / 94 - R1 PAGE 4 OF 28

between branch and main run, and to provide vent ing during welding and heat treatment operations. If the reinforcement pad is made in more than one piece, each piece shall be provided with a vent hole. The material of reinforcement pads shall be the same as the main run pipe. An examination of the welds joining reinforcement pad to the branch shall be made by FEDO Engineer/ representative before installing the reinforcement pad. FABRICATION TOLERANCES To avoid misalignment when joining a pipe or fitting to a pipe, the pipe or fitting shall be turned to check for any irregularities and shall be joined correctly. Unless otherwise specified, tolerances for fabrication shall be in accordance with the requirements shown in Figure 6. GALVANISED PIPING Galvanised carbon steel piping shall be completly cold worked so as not to damage galvanised surfaces

3.0.0

WELDING SPECIFICATION

3.1.0 3.1.1

GENERAL This specification shall be adopted to all welded pipe joints of carbon steel, alloy steel and stainless steel piping system. The welded pipe joints are defined as under: 1. All line joints of the longitudinal and circumferential butt welded and socket welded type. 2. Attachments of castings, forgings, flanges and other supporting attachments to pipes. 3. Welded manifold headers and other sub assemblies 4. Welded branch connections with or without reinforcement pads. 5. Manufacture of welded / fabricated piping components. 6. The attachment of smaller connections for vents, drains, drips and other instrument tappings. All welding, and heat treatment, shall be in accordance with the applicable codes and specifications.

3.1.2

3.1.3

a.

codes for petroleum refinery piping

ANSI B31.3

b.

Welding Qualifications.

ASME Sec. IX.

c.

Code of procedure for metal arc welding of mild steel (structural work only)

IS : 823

d.

The Indian Boiler Regulations

IBR

All codes referred shall be the latest editions. In adition to the codes mentioned above, other relevant international codes such relating to the work, shall also be applicable. In case of conflicts between different codes or between codes

FACT ENGINEERING AND DESIGN ORGANISATION

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION

3.2.0 3.2.1

and tender specifications the more stringent shall be applicable. INSPECTION & TESTING General 1. The owner’s inspector shall have free access to all concerned places, where the actual work is being performed. The contractor shall also provide the owner’s inspector all means and facilities necessary for carrying out inspection. 2. The owner is entitled to depute his own inspector to the field or shop where prefabrication and erection of pipe lines are being done with ( but not limited to ) the following functions :

a. b. c. d. e. f.

b. To supervise welding procedure & welders performance qualification tests. c. To ensure that only qualified welders are engaged for welding. d. To check that shop / field welding is in conformity with the relevant specification and codes of practice followed in pipe line construction.

g. h. i. j.

e. To carry out Non Destructive Examination of welds.

3.2.3

3. Contractor shall intimate sufficiently in advance the commencement of qualification tests and welding work to enable the owner’s inspector to be present to supervise them. Welding procedure qualification Welding procedure qualification shall be carried out in accordence with the job requirements and relevant requirements laid down in the standard ASME Sec. IX and other relevant applicable codes. The contractor shall submit the welding procedures in QW — 482 format given in ASME Sec. IX. immediately on receipt of work order. Owner’s inspector will review, check and approve the welding procedure after conducting the necessary tests. It shall be the responsibility of the contractor to carry out the tests, at his costs. All the necessary arrangements for the procedure qualification i.e. supply of material for assembly welding consumables, welding equipments, preparation of test coupons, welding, heat treatment, machining of test specimen, conducting N.D.T, mechanical & chemical test and maintaining qualification records, shall be by the contractor at his cost. He shall submit the test results to the Engineer-in-charge in QW483 format given in ASME Sec. IX. for approval. Welder’s Qualification 1. Welder’s qualification shall be in accordance with the relevent codes specified in scope of work. Owner’s inspector shall witness the test and certify the qualification of each welder. Contractor shall submit the welder qualification report as per Format before the commencement of work. It shall be the responsibility of the contractor to carry out the qualification tests of welders.

PAGE 7 OF 28

For piping covered by Indian Boiler Regulations, welders with valid IBR certificate, qualified by Boiler Inspectors and acceptable to the local Boiler Authority shall only be employed. 2. The welders shall always have in their possession the identification card as per Format and shall produce it whenever demanded by owner’s Inspector. It shall be the responsibility of the contractor to issue the identity cards after duly certified by the Inspector. 3. The identity card shall contain the following minimum details.

a. To check the quantity, consumables and welding equipments used on the job

3.2.2

25ES205 / 94 - R1

FABRICATION & ERECTION OF STEEL PIPING

3.3.0 3.3.1

3.4.0

3.4.1 3.4.2

3.4.3

Name of Contractor Name of welder Stamp No. Address Recent passport size photograph Details of qualifications i Welding process and P numbers ii Range of pipe diameters iii Range of thickness iv Welding positions Date of qualification test Period of validity Signature of manufacturer Signature of Engineer —in—charge

4. No welder shall be permitted to work without the possession of identify card. 5. If a welder is found to perform a type of welding or in a position for which he is not qualified, he shall be debarred from doing any further work. All such welds so performed shall be cut and redone at the expense of the Contractor. 6. Engineer-in-charge reserves the right to ask the contractors to perform requalification test at their cost for welders whose workmanship technique etc. are found unsatisfactory during the execution of the job. SELECTION OF WELDING MATERIALS Selection of welding electrodes shall be as per Appendix - II Table - I : Selection of welding electrodes & rods for joining similar materials except Aluminium Table - II : Selection of welding electrodes & rods for joining dissimilar materials except Aluminium STORAGE AND ISSUE OF ELECTRODES Electrodes shall be stored and issued as follows: Electrodes shall be stored indoors free from moisture as far as possible. Electrodes shall be dried in a heating cabinet in accordance with the manufacturer’s recommendation before welding. Immediately after drying, electrode shall be stored in a portable dryer, or in a heating cabinet at the following temperature, and shall then be used. a.

Illumenite

FACT ENGINEERING AND DESIGN ORGANISATION

: 70 - 1000C

ENGINEERING SPECIFICATION b.

3.4.4

3.4.5

3.4.6

3.4.7 3.5.0 3.5.1

3.5.2

3.6.0 3.6.1

3.6.2

Others

FABRICATION & ERECTION OF STEEL PIPING : 100 - 1500C

During welding, electrodes shall be kept in a portable dryer or equivalent. The electrodes shall not be laid down directly on the ground or any other damp places. Electrodes exposed to the atmosphere for more than 4 hours shall be redried. However, only two redryings are permitted. When the day’s work has been completed, the electrodes shall be collected and stored in a heating cabinet at the temperature specified in 3.3.2 above. Issue of electrodes shall be controlled by the assigned person. SURROUNDING CONDITIONS FOR WELDING Welding shall not be performed under the following climatic conditions. 1. In the rain 2. In winds of 8 m/s or more 3. In snow However, welding may be performed if the area is fully protected from the inclement weather. When the item to be welded is wet with rain or covered with snow or ice, the snow or ice shall be removed and the surface dried completely before welding. GENERAL FOR WELDING Welding shall be performed in accordance with welding procedure specification (WPS), which has been approved by FEDO/Representative. Before welding, the WPS shall be prepared which has been qualified by the welding procedure qualification test based on the specification for welding procedure qualification, according to this specification and ASME Section IX. As a general rule, welding for steel pipes shall be performed as follows. 1. The welding process used shall be SMAW, GTAW, or GMAW (MIG Welding). Any other welding process may be used only when approved by FEDO / Representative. 2. Preferably, the first layer of butt welded joint shall be made by GTAW. For the first layer on 3Cr. and higher low-alloy steel pipe, or stainless steel, GTAW shall be performed with back shielding gas such as argon. 3. The surface to be welded shall be cleaned thoroughly and any paint, rust, scale, oil, dust, moisture, or any other foreign matter that would be detrimental shall be removed at least within the extent of 50mm from the groove end before welding. 4. The welding position shall be performed in flat position as far as possible. 5. Full consideration shall be given to the welding progression to keep distortion to a minimum. 6. In multi-layer welding, before welding the following layer, the surface of each layer

3.7.0 3.7.1

3.7.2 3.7.3

3.7.4

3.7.5

25ES205 / 94 - R1 PAGE 8 OF 28

shall be removed of any slag or other foreign matter with a chipping hammer, a grinder, or a wire brush. To prevent spatter adhering to the base metal, a spatter deposit prevention paint may be applied around the outside of the groove. Wire brushes and abrasive wheels shall be distinguished so that those for stainless steel shall not be confused with those for carbon steel or low-alloy steel. Moreover, any arc starts, craters, or inferior beads of each layer shall be removed before the welding is continued. 7. Peening on the welds is prohibited. 8. Unless required, the external surfaces of welds shall not be finished with a grinder or any other tool. However, when finishing the end of weld beads with a grinder, special precautions shall be taken not to reduce the thickness of base metal by over grinding. 9. Arc strike shall not be generated on the pipe surface. Care shall be taken not to lay down the electrode holder or move it around by the electrode. 10. To prevent damage from sparks, care shall be taken to ground the welding equipment by strict use of ground clips and to ground each piece of material. 11. When welding galvanized steel, the coating shall be removed from the surface to be welded, 50mm on either side. 12. For the joints of P-Number 5 materials, when welding is unavoidably interrupted, postheating shall be applied and the welds shall be cooled gradually by the use of insulation or other suitable materials. ( Para 4.3.0 ). BUTT WELDS When welding a pipe to a pipe, fitting, valve, etc., the components shall be placed on a revolv ing stand, aligned accurately within the tolerances specified in Section 2.8. of this specifica- tion by the use of tack weld pieces (fit-up pieces), lineup clamps, etc., and shall then be welded. Backing rings shall not be used unless otherwise specified. The number of tack welds made shall be the minimum required to secure the pipe, and a minimum of three shall be made for pipes of 50 NB and larger. When tack weld pieces are used for pipe materials of stainless steel,the material of the pieces shall be similar to that of the pipe. When the pipe material is low-alloy steel, carbon steel may be used for the pieces unless otherwise specified.The welding for the tack weld pieces shall be performed with electrodes equivalent to those used for the base metal and shall be performed by a welder or welding operator qualified for fillet welds. Tack welds, which are made directly at the root of the joint, shall be made by a qualified welder or welding operator specified in Section 3.2.3 and shall be made by the same welding procedure as the product welding. Tack welds that are cracked or not fused properly shall be removed.

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION 3.7.6

3.7.7.

3.7.8.

3.8.0 3.8.1

3.9.0 3.9.1

3.10.0

3.10.1

3.10.2

3.10.3

3.10.4

FABRICATION & ERECTION OF STEEL PIPING

Pieces for tack welds shall be removed with a grinder. If a concave surface due to overgrinding, etc., is produced on the pipe, the repair welding shall be performed in accordance with WPS, which has been approved by FEDO Engineer / Representative. Any convex weld beads formed on the pipe surface shall be removed. When defects are found while removing tacks / cleats they shall be fully removed, repaired by welding, and a magnetic particle or liquid penetration examination shall be performed to confirm that there are no defects. Internal weld protrusions of butt welds for orifice flanges shall be finished smoothly to the pipe inside diameters with a grinder. The root pass of all buttwelds on pipe of size less than 50NB shall be made in GTAW grove only. FILLET WELDS Fillet welding shall be performed as follows: 1. Fillet welds shall be multi-layered and of sufficient strength. 2. Fillet welds shall be as shown in Figures 7A and 7B. 3. Fillet welds for socket welding flanges shall be as shown in figure 7C. 4. Fillet welds for socket welding components shall be as shown in figure 7D. SEAL WELDS Seal welding shall be performed as follows: 1. Threaded joints to be seal welded shall not be coated with a compound or covered with a seal. After any oil on the threads has been fully removed, the threads of joint shall be screwed in securely in accordance with Section 5-1.0, and shall then be welded. 2. If threaded joints are seal welded, all exposed threads shall be covered by a seal weld. 3. Seal welding shall be performed by a qualified welder. 4. Electrodes of 3.2 mm dia or less shall be used. FLANGE ATTACHMENT WELDS Flange attachment welding shall be performed as fol lows: Unless otherwise shown on the drawings, in principle, flange bolt holes shall straddle the established centerlines. The only exception is at equipment flanges required for matching orientation. When installing flanges, flange square or other jig shall be used, and the center line of the pipe and the perpendicular of the flange face shall be within the tolerances specified in Section 2.8. Joining welding neck flanges to the pipe shall be performed in accordance with the requirements of Section 3.7. Front welding shall be performed on slip-on flange joints except for pipes class less than 50NB (Figure 8). Care shall be taken so that the weld reinforcement does not protrude on to the

25ES205 / 94 - R1 PAGE 9 OF 28

gasket contact face and that the gasket contact face is not damaged by welding. If the gasket contact face is damaged,or weld reinforcement protrudes onto the gasket contact face, such defects shall be removed by polishing the gasket contact face. 3.10.5 When welding flange joints, care shall be taken to handle the flanges carefully so that the gasket contact face will not be damaged. The gasket contact face shall not be in direct contact with the ground, and grounding shall not be taken directly from the gasket contact face. 3.10.6 In the case slip-on flanges which are to be heat treated, and also require to be front welded,they shall be provided with a 3mm dia vent hole at the hub as shown in FIG.8.

4.0.0

HEAT TREATMENT

4.1.0 4.1.1

PREHEATING Unless otherwise specified, the preheating applies to gas cutting and welding (all welds including butt welds, fillet welds, socket welds, repair welds, tack welds, and seal welds of thread ed joints ). Preheating shall be performed as follows: 1. Materials to be pre heated and preheating temperature shall be in accordance with relevant codes as a rule, but for steam lines fallen under the purview of IBR, the same shall be followed. 2. If the maximum specified carbon content is more than 0.38, or if the material is under a high degree of restraint (weld-all- around such as pipe shoe), carbon steel shall be preheated to a minimum of 800C and maintained at that temperature for surface welding. 3. When welding dissimilar metals, unless o th er wise sp eci fied , the preh eatin g temperature shall be that for the higher grade steel 4. The width of the heated circumferential band shall be 4 times the pipe nominal wall thickness or 100mm, whichever is greater, extending on both sides of the welds. 5. Heat shall be applied by the use of a gas burner or a heating coil. The use of a gas burner for cutting shall not be permitted since it tends to heat locally. Temperature measurements of preheating, interpass temperature, and postheating shall be performed by a temperature crayon ( tempil stick), thermocouple temperature indicator, etc., and it shall be confirmed that the specified temperature is maintained. INTERPASS TEMPERATURE The following items shall be confirmed for interpass temperature: 1. Interpass temperature of the materials that require to be preheated shall be the same as the preheating temperature and shall be maintained until welding has been completed. 2. Interpass temperature of austenitic stainless steel pipe shall not exceed 1500C.

4.1.6

4.2.0 4.2.1

FACT ENGINEERING AND DESIGN ORGANISATION

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION 4.3.0 4.3.1

4.4.0 4.4.1

25ES205 / 94 - R1

FABRICATION & ERECTION OF STEEL PIPING

POSTHEATING When postheating is required it shall be carried out for more than 30 minutes within the temperature range of 300 to 4000C, and the material shall be cooled gradually by the use of insulation, etc. However, when post weld heat treatment is performed immediately after welding, post - heating is not necessary. POST WELD HEAT TREATMENT Procedure Unless otherwise specified, post weld heat treatment shall be performed in accordance with the following procedure. However, post weld heat treatment for dissimilar metals shall be in accordance with the individual specification. 1. The requirements for heat treatment shall be in accordance with applicable codes. But for steam lines IBR shall be followed. Heat treatment of welded joints between dissimilar ferritic metals shall be within the temperature ranges for the higher grade steel. 2. Al l th e m ach ine d surf aces sha ll be protected adequately by the use of paint or compound to prevent damage from scaling during heat treatment. 3. In case of furnace heat treatment, all the pipes shall be supported properly during heat treatment to minimize warps and other distortions. 4. In principle, after heat treatment has been completed, neither rewelding nor reheating shall be performed. However, if rewelding is performed because of repairs, etc., heat treatment shall be performed again. 5. If welding is intrrupted before completion or the weldment is allowed to cool prior to heat treatment, adequate heat treatment or controlled rate of cooling shall be applied to ensure that no effects detrimental to the piping shall result. The pre-heat temperature in the welding must be applied before welding is resummed. 6. When heat treatment is performed, the holding temperature, holding time, rate of heating and cooling, and the hardness after heat treatment required shall be recorded and the records shall be submitted to FEDO Engineer / Representative. 7. The measurement of heat treatment temperature shall be performed by measuring the metal temperature by the use of a thermocouple,or by other suitable methods. Ho w e ve r, w he n t he h e at t r ea t me n t temperature is measured by the furnace temperature, the relation between the temperature of metal and furnace shall be considered. 8. A hardness test shall be performed in accordance with Section 9.4.0 to determine if the heat treatment has been performed satisfactorily. 9. Throughout the cycle of heat treatment, the portion out side the heated band shall be suitably wrapped under insulation so as to avoid any harmful temperature gradient at

PAGE 11 OF 28

the exposed surface of pipe. For this purpose temperature at the exposed surface of pipe should not be allowed to exceed 4000C. 10. All online pipe item ( eg. Valves, Instruments etc. )within 500mm of the weld which is beingheat treated, shall be dismantled prior to commencement of heat treatment of weld. 11. The no. of thermocouples to be used for the monitoring of tempreature shall be as follows.( HAZ - Heat Affected Zone ) DIA OF PIPE

NOS. OrientatIO N(0)

LOCATION

15NB & below

2

0 , 180

One on weld & one in HAZ

200 to 500 NB

3

0 , 120 , 240

one on weld & rest in HAZ on either side of weld

600 Nb & above

4

& rest in 0 , 90 , two on weld either side 180 , 270 HAZ on of weld

4.4.2

Heating Methods For heat treatment, application of heat in a furnace is preferable, however, heat may be applied locally by the following methods: 1. Heating by electrical resistance This is a method where a programmed movable automatic heater applies heat by means of nickel-chrome wire applied around the welds. Special attention shall be given to the following items: a.

Protective measures shall be taken to prevent damage to the pipe surface or injury to the workers due to a short circuit of the lead wire, and to prevent persons other than the operator entering the work area.

b.

The width to be heated shall extend 25mm beyond the edges of the weld on each side

c.

The width to be insulated shall extend at least 150mm on each side of the weld.

d.

The heating and cooling rates above 3150C shall be determined by the following formula, but in no case shall the rate exceed 2200C per hour. 25 x 220 ( oC ⁄ h) wall thickness (mm)

2. Heating by gas burner a.

This is a method where heat is applied by a propane or butane gas burner. This method shall not be used unless specified by FEDO Engineer/ Representative.

5.0.0

THREADED AND FLANGED JOINTS

5.1.0

THREADED JOINTS Threading of joints shall be as follows. Taper pipe threads shall be as per ANSI B2.1,

5.1.1

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION

FABRICATION & ERECTION OF STEEL PIPING

ANSI Standard Taper Pipe Thread (NPT). Unless otherwise specified, when threading on pipes of NPS 11/2 or smaller, the pipe thickness shall be Schedule 80. 5.1.3 In principle, all threads shall be cut with a threading machine or lathe. When threading with hand dies such as an oster or reed type, a lubricant shall be used to avoid an irregularity of screw thread or scratches due to coarse machining. 5.1.4 All the threads shall be cleaned thoroughly. 5.1.5 In principle, teflon seal tape shall be used for threaded joints used in services of 1500C and lower. Once the joints are screwed, they shall not be unscrewed. Fillers such as hemp, jute, lead scraps, and white paint shall not be used. 5.1.6 Seal welding of threaded joints shall be in accordance with Section 3.9 5.1.7 In no case shall threaded joints be made with a length of engagement less than specified. 5.1.8 When pipe is screwed into a threaded flange, the pipe end shall not extend beyond the gasket contact face. If the pipe end protrudes even slightly, the pipe end shall be ground off with a grinder or a file so that the gasket contact face is not scratched. 5.1.9 When screwing a pipe into a threaded bronze valve, the pipe shall be gripped by a pipe vice and the valve shall be screwed on by clutching the end of the valve with a wrench. Threading and screwing shall be carried out carefully so that the pipe does not enter the valve too far and damage the valve due to the threads being overcut on the pipe. 5.1.10 Scraps of metal due to threading and oil used for cutting shall be removed before screwing on instrument air piping. 5.1.11 Any compound or lubricant used on the threads shall be suitable for the service conditions, and shall not react unfavourably with either the service fluid or piping material. 5.2.0 FLANGED JOINTS Flanged joints shall be made as follows: 5.2.1 In principle, Class 125 and 250 flanges of valves and other equipment made of gray cast iron shall be of flat face with full contact area gaskets. 5.2.2 Steel to gray cast iron flanged joints shall be assembled with care to prevent damage to the cast iron flange. 5.2.3 Unless otherwise specified, gasket paste shall be applied uniformly on the gasket contact face of the flange when a metal jacketed gasket or a metal gasket is used. However, when the flange material is austenitic stainless steel, the use of gasket paste shall be approved by FEDO Engineer / Representative. As the choice of paste is limited by the fluid handled, the paste shall be suitable for the service fluid. The gasket paste shall be kept in a container with a lid and handled with care to prevent entry of sand, dust or other foreign matter. 5.2.4 For asbestos-sheet gasket, gasket paste may not be applied. 5.2.5 For spiral-wound gaskets or ring-joint gaskets, gasket paste shall not be applied.

5.2.6

5.1.2

5.2.7 5.2.8

5.2.9

5.2.10

5.2.11

5.2.12

5.2.13

5.2.14

5.2.15

25ES205 / 94 - R1 PAGE 12 OF 28

The thread and bearing surfaces of bolts and nuts to be used on piping at temperatures of 2500C or higher shall be coated thinly and uniformly with a lubricant to prevent them becoming burnt and stuck. Lubricant shall not be applied to machine bolts unless other wise specified. Bolts shall be of material and length as specified. In principle, all the bolts shall extend 2 or 3 threads through their nuts. Flanges shall be tightened with a wrench or spanner of the specified length and with a hammer if required, or with a torque wrench. Care shall be taken so that the bolt is not tightened excessively or unevenly. As the tightening force varies according to the flanges, gaskets, and bolts used, the tightness shall be controlled with care. In particular, flanges of piping for low temperature and dangerous services shall be tightened only with a torque wrench. For large diameter bolts, the use of an impact wrench with torque control or a power machine ( hydraulic torque wrench ) is preferred. Bolts of flanged joints shall be successively and evenly tightened in a symmetrical pattern ( Appendix IV ). Cast iron flanges of equipment such as pumps, turbines, compressors, or other similar equipment shall be tightened carefully so that the flange does not break. The flange clearance with connections of pumps, compressors, or other similar equipment, and ring-joint flanges shall be measured by the use of a clearance gauge and the parallelism shall be checked, and then the bolts shall be tightened evenly. Ring-joint gaskets shall be ground with the groove of the flange for a tight fit prior to installation. The grinding shall be performed by using a compound (coarse, intermediate, or fine), and red paste shall be applied to confirm the roughness of the contact face between the ring and the groove of the flange. The paste shall be removed completely before the ring is installed. If the gasket contact face of the flange is damaged, the defects shall be removed by polishing evenly the gasket contact face, or the flange shall be replaced.

6.0.0

PROTECTION OF PREFABRICATED PIPE SPOOLS AND SIZE

6.1.0

PROTECTION OF PREFABRICATED PIPE SPOOLS All prefabricated pipe spools that have been inspected shall be protected as follows until they are installed in a plant. 1. All dust, rust, weld slags, or other foreign matter in the pipe shall be removed carefully by brushing or by flushing with compressed air, or by other suitable means. After cleaning, all openings of austenitic stainless steel shall be blanked. 2. Pipe spools to be stored temporarily shall be laid on suitable sleepers and not directly on the ground.

6.1.1

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION

6.1.2

6.1.3

6.2.0 6.2.1

6.2.2

FABRICATION & ERECTION OF STEEL PIPING

3. Pipe spools shall be marked with the area number (major divisions such as offsite, onsite), line number, and piece number. After cleaning the pipe spool surface and applying rust preven tive, it shall be marked clearly with paint by the use of a stencil. When specified, in showing the line number, etc., a color code identification or tag plate (die stamped to the sheet metal) for each area shall be made, and it shall be attached with coated iron wire. However, zinc coated iron wire shall not be used for austenitic stainless steel. 4. If hydrostatic test is performed, the water shall be removed completely. When prefabricated pipe spools are to be stored for a long period of time or are to be shipped, the pipe interior shall be checked to see that it is clean, and the openings of pipe ends shall be protected as follows: 1. When the pipe ends are prepared, the ends shall be coated with rust preventive ( Appendix — 1 ) and covered with a plastic cap, etc. 2. When the pipe ends are flanged, the gasket contact face shall be coated with rust preventive and be protected with a wooden or plastic cover bolted on to the flange. In case of a wooden cover, poly ethylene or other suitable film shall be inserted between the flange and the cover. 3. When the pipe ends are threaded, the threads shall be coated with rust preventive and threaded end connections shall be covered with wooden or plastic plugs or caps. 4. When masking tape is intended to be used instead of the protection mentioned above, it shall be subject to FEDO Engineer’s/ Representative’s approval. However, austenitic stainless steel pipes and prefabricated pipe spools that may be affected by chlorine ions, shall be protected in accordance with the individual specification. SIZE OF PREFABRICATED PIPE SPOOLS The size of prefabricated pipe spools shall be determined by consideration of the conditions of transportation, etc. Consideration shall be given to the conditions of inland transportation, size of the carrier’s hatch, means of transportation, traffic regulations in the country and the economy. The standard size of a package to transport prefabricated pipe spools is limited to 2.5 meters width by 2.5meters height by 13 meters length with a weight of 5 tons per package.

7.0.0

INSTALLATION OF PIPE SUPPORTS

7.1.0 7.1.1

PIPE SUPPORTS Pipe supports whose materials & dimensions conform to fabrication drgs, shall be installed accurately at the positions shown on the drawings prior to piping installation. When installing the pipe supports, pay attention to the following: 1. Each support shall be fabricated and assembled so that piping does not become disengaged from the support by movement of the piping itself due to operation.

7.2.0 7.2.1

7.3.0 7.3.1

7.3.2

7.4.0 7.4.1

7.5.0 7.5.1

25ES205 / 94 - R1 PAGE 13 OF 28

2. Stanchions requiring foundations shall have anchor bolts of the correct size, position, projection, etc. 3. Before installing the supports, the finished conditions of the cut ends of all members and welded conditions shall be checked. 4. Pipe supports shall be made level and plumb to facilitate alignment during piping installation. 5. In principle, when the main run pipe is lowalloy steel or ss, either a pad plate or support members of the same material as the main run pipe shall be used, and carbon steel supports shall not be welded directly to these. In this case, when welding the pipe to the support, the same electrodes as applied to the pipe shall be used, and the qualified welder specified in Section 3.1.0 shall perform the welding in accordance with WPS. When the main run pipe requires heat treatment, the welds for attachment of pipe supports shall be heat treated if required,as per ANSI B31.3. 6. Welds for anchor supports shall be doublelayer welds to provide a bond of sufficient strength. 7. When welding dummy pipe to elbows, tees, etc., the welding shall not melt through to their interior. SLIDING SUPPORTS Sliding supports shall be assembled so that the expected movement of the supported piping due to thermal expansion and contraction or other design requirements is possible. SPRING HANGERS The lock-pin or preset-piece of spring hangers shall not be taken off until pressure testing and flushing have been completed, except only when a high temperature fluid such as flushing steam is streamed. Adjustment of spring hangers shall be performed by taking off the lock-pin or preset-piece prior to ini tial operation. It shall be confirmed that spring hangers operate on the expected movement according to temperature increase in the initial operation. ADDITIONAL SUPPORTS If additional supports are required to prevent shaking of piping in the field, they shall be installed in accordance with the instructions of the FEDO Engineer’s / Representative’s Engineer in consideration of the effects due to thermal expansion of the piping. INSULATION SUPPORTS The configuration, material, and installation procedure of support rings for hot or cold insulation of vertical piping shall be in accordance with the individual specification.

8.0.0

PIPING INSTALLATION

8.1.0

GENERAL ITEMS FOR PIPING INSTALLATION The general items for attention relating to piping installation shall be as follows:

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION 8.1.1

FABRICATION & ERECTION OF STEEL PIPING

Pipes shall be stored in accordance with each category of material, and stacked on sleepers with wedges or stakes provided to prevent the stack from collapsing. 8.1.2 Before installation, pipe spools shall be checked with the piping drawings as to dimensions, material, class, etc. In principle, the installation of pipe spools shall start from elevated lines or larger size lines. The precedence for installation shall be determined after confirming that all equipment has been installed and aligned, and steel structures and pipe racks are ready for installation of the piping. The part which cannot be painted after piping installation shall be painted beforehand. 8.1.3 In principle, underground piping shall be installed before above ground piping. 8.1.4 Before installation, the pipe spool shall be suspended at one end by a crane, etc., and ham mered to remove the dust inside. 8.1.5 Supports such as stanchions shall be checked for the accuracy of position, dimensions, elevation, levelness and plumbness. 8.1.6 When temporary supports are installed unavoidably to the piping, welding shall not be performed on the main run pipe. 8.1.7 Temporary work for piping installation shall be planned in advance, and the necessary equipment and materials shall be selected and prepared in time with the schedule. Moreover, the scaffolding required for field connections shall be checked, and whether the required number of scaffold pipes and boards shall be sufficient. 8.1.8 Scaffolding shall be provided to permit safe operation, and the use of small size piping, pumps, instruments, etc., in lieu of scaffolding shall be prohibited. All scaffold boards shall be securely tied to the scaffold pipes or piping with metal connectors or iron wire. 8.1.9 The primary cards, cables, and grounding wires of all welding equipment shall be of sufficient size, and any conductors with damaged insulation shall not be used. They shall be inspected periodically. 8.1.10 Piping components such as pipe spools and valves shall be lifted with the designated wire rope slings, and the use of iron wire shall be prohibited. 8.1.11 Piping components shall be hauled by mechanical equipments as far as possible. Even for a short haul, the components shall be securely tied to prevent them from falling. 8.1.12 Piping requiring cold spring may become misaligned during field welding, therefore, the dimensions shall be checked thoroughly in accordance with the piping drawings. After it has been confirmed that guides and anchors have been installed at the specified location, the piping shall be installed. Furthermore, when there are flanged joints in the same direction requiring cold spring, a spacer with the same thickness as the dimension of cold spring shall be inserted between the flanges, and when the entire piping system has been assembled, the spacer shall be removed and the flange fastened.

25ES205 / 94 - R1 PAGE 14 OF 28

8.1.13 Alignment tolerances of flange connections installed in piping shall be as per Figure 9 ( Page 28 of 28 ). However, alignment tolerances of pipe flanges for the rotational equipment nozzle shall be as per Section 8.3.0 ( Item 6 ). 8.1.14 In principle, the longitudinal welded joint of welded pipe shall be located above the horizontal centerline, if the pipe is installed horizontally. 8.2.0 PIPING AROUND COLUMNS, DRUMS AND HEAT EXCHANGERS The piping installation around columns, drums, and heat exchangers shall be as follows: 8.2.1 Piping for columns shall be installed in the order of the overhead line and the risers, and the installation of instrument take-off nozzles, supports, spring hangers,etc. The levelness and plumbness of piping shall be complete and true. 8.2.2 For piping installed at high elevations at the top of columns, drums, etc., assembly and nondestructive examination and pressure testing shall be performed on the ground, as far as possible, to minimize work at high elevations. When piping installation is unavoidably performed at high elevations, the area below shall be fenced in with a safety rope and “MEN AT WORK ABOVE” signs shall be posted. 8.2.3 When piping components are to be lifted into place at high elevations by means of large cranes, in advance, the work data such as the weight, position of center of gravity, reach of crane, crane boom length, and other vital data shall be ob tained, and they shall be studied sufficiently. 8.2.4 Temporary supports shall not be taken from the shell (body) of equipment. 8.2.5 After the pipe spool has been installed accurately to the nozzle of the equipment, field welding shall be performed. In such cases, blinds shall not be inserted for purposes of pressure testing, etc. 8.3.0 PIPING AROUND PUMPS AND COMPRESSORS The piping installation around pumps and compressors shall be as follows. 8.3.1 All piping except for the connections to the nozzle of rotating machinery shall be assembled on the ground. 8.3.2 Before installation of piping to rotating machinery, the required heat treatment, pressure test ing, interior cleaning, etc., shall be completed. Pressure testing shall not be performed by inserting the blinds directly between the nozzle of rotating machinery and the flange of the connected piping. 8.3.3 The protective cover placed on the nozzle of rotating machinery shall not be removed until the piping is to be connected. 8.3.4 The preset-piece of spring hangers shall be taken off and spring hangers shall be adjusted, so that piping is located accurately. 8.3.5 It shall be confirmed that alignment work of rotating machinery and measurement preparation for inspecting misalignment has been completed.

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION 8.3.6

8.3.7

8.3.8

8.3.9

8.4.0

8.4.1

8.4.2 8.5.0

8.5.1

8.5.2

FABRICATION & ERECTION OF STEEL PIPING

Pipe flanges shall be aligned with all the nozzles of rotating machinery. The alignment shall be performed by the adjustment of pipe supports and flange connections. Unless otherwise speci fied, the misalignment between flanges shall be within the following permissible limits: a.

Flange face separation ( space for gasket )

: ± 0.8mm

b.

Flange face parallelism

: 0.2mm

c.

Rotational offset

: 0.8mm

d.

horizontal and vertical bolt hole offset

: 0.8mm

If the piping alignment specified in Item (6) above is not within the permissible limits, it shall be corrected. The correction of piping alignment or the adjustment work of supports shall be performed by dismantling piping from rotating machinery. Care shall be taken so that expansion or distortion due to welding, etc., does not have a detrimental influence on the rotating machinery. When connecting piping to a rotating machine, if the machine misalignment is more than the values specified, alignment work of the machine and piping shall be performed again by dismantling the piping from the machine. After piping is connected to rotating machinery, the rearrangement of pipe supports or retightening of flange bolts shall not be performed without permission. PIPING AROUND FIRED HEATERS Piping installation around fired heaters shall be as follows: Since piping around the burner tends to become complicated, piping for one or two burners shall be installed first, and after confirming operability, clearance, safety, and other matters, other piping shall be installed. Drain piping around the burner shall not be placed on the ground or in such a way as to obstruct passage of persons. PIPING ON PIPE RACK Piping installation on pipe rack shall be as follows: Generally, since air cooled heat exchangers are placed on top of the pipe rack, and pumps are placed underneath, the precedence for installing piping shall be determined in consideration of the time of installing such equipment, the number of stages of the pipe rack itself, etc. In principle, piping installation will be performed from the bottom to the top level. When installing piping, a check shall be performed to ensure that the pipe rack beams have been painted. Before connecting piping to other equipment, piping on pipe racks shall be laid down accurately in the places specified beforehand, and then slide shoes and stoppers shall be installed accurately in accordance with the drawings, so that baseline for dimensional adjustments in field installation may be made. However, elbows, tees, etc., required for take-off connections to outside the pipe rack may be left in place temporarily since it may be re quired to perform

8.5.3

8.5.4 8.6.0 8.6.1

8.6.2

8.6.3

8.6.4 8.6.5

8.6.6

8.6.7

8.7.0 8.7.1

8.7.2

8.7.3

8.7.4

8.7.5

25ES205 / 94 - R1 PAGE 15 OF 28

adjustments. After the pipe has been laid on the rack, the pipe shall be tied with wire to prevent it from falling off until the weld joints are made. The pipe fittings and welded lines shall be installed so as not to be positioned on the beams. OFFSITE PIPING Installation of offsite piping shall be as follows: Piping installation inside the dike shall be performed after a thorough study of the work schedule has been made, with consideration given to other related work such as the confirma tion of time of tank water filling and of access for handling materials. Pipe sleepers and support footings inside the dike shall be installed after confirming that the levelness of the ground has not been disturbed by the water filling test of the tank. Piping to be connected to the tank nozzle shall be installed after checking that the valve and accessories installed on the tank are in accordance with the specification. Flexible hoses and expansion joints to the tank nozzle shall be installed accurately in accordance with the drawings. When laying pipe on sleepers, the sleepers shall be checked to confirm that they are at the specified elevation, level in line, and painted. Piping on pipe sleepers shall be laid on sleepers that have been marked off. Slide shoes and stoppers shall be installed accurately in accordance with the drawings. The pipe fittings and welded lines shall be installed so as not to be positioned on the sleepers. For piping penetrating an oil dike, the flanged, threaded, or welded joints shall not be embedded in the dyke. INSTALLATION OF VALVES The installation of valves shall be as follows: The valve shall be installed accurately so that its location and the orientation of the handle is in accordance with the piping drawings. However, when the orientation of the handle is deemed inappropriate from the viewpoint of operation or passage, the FEDO engineer shall be contacted for directions. The valve shall be checked for its class, body materials, and trim materials to prevent any misuse. Before installing the valve, the flange faces of the valve and the connected piping shall be checked to see that they are not damaged or dirty, and that they are parallel with each other. Valves shall be installed in the closed position, except for plug valves and ball valves. After being installed, valves shall not be opened except for pressure testing. Especially, welding for installation of the butt weld and socket weld type valves shall be performed in the closed position, to prevent the valve seat being damaged. For lubricant plug valves, the disc shall be left in the open position and the lubricant shall be replenished to prevent loss of the sealant.

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION

FABRICATION & ERECTION OF STEEL PIPING

8.7.6

Globe valves, check valves, control valves, and other similar valves shall be installed in accord ance with the marked direc tion by checking the flow direction. 8.7.7 To prevent the stem threads from rusting, grease shall be applied prior to installation of the valve. 8.8.0 INSTALLATION OF SAFETY VALVES The installation of safety valves shall be as follows: 8.8.1 Until line pressure testing has been completed, in principle, the safety valves shall not be in stalled with the piping. If safety valves are necessary to assemble the piping, a spool of the same face-to face dimension shall be fabricated and installed. For threaded safety valves, the piping shall be capped. However, the safety valve with test gag may be installed with piping and subjected to line pressure testing. 8.8.2 All safety valves shall be installed after the specified set pressure has been tested in the field. 8.8.3 The seal securing the cap to the safety valve body shall not be removed without FEDO / Representative’s approval. 8.8.4 The safety valve with a lever shall be installed with the lever oriented as shown on the drawing. 8.9.0 Installation of expansion joints The installation of expansion joints shall be as follows: 8.9.1 Expansion joints shall be installed accurately and shall be at the location and of the dimensions shown on the piping and detailed drawings, and in a manner so as not to be connected eccen tric with the pipe. 8.9.2 Expansion joints shall be installed after confirming that the line has been completely assembled with all anchors, guides, and stoppers installed in place as shown on the piping drawings. 8.9.3 Expansion joints shall be installed so that no stress except in the direction intended occurs. 8.9.4 After pressure testing and flushing, all shipping bolts and fixtures shall be removed and the joints shall be checked to ensure that nothing obstructs the expansion movement. 8.9.5 Prior to installation, expansion joints with inner sleeves shall be checked to ensure that the sleeve inlet (fixed) is on the upstream side. 8.9.6 Bellows of expansion joints shall be handled with utmost care, so that no objects will be dropped upon it. 8.9.7 Each expansion joint shall be blown free of dust / foreign matter with compressed air or shall be cleaned with a piece of cloth. 8.9.8 For handling and installation of expansion joints, great care shall be taken while aligning. An expansion joint shall never be slinged with bellows corrugations/external shrouds, tie-rods, angles etc. 8.9.9 An expansion joint shall preferably be slinged on the end pipes/flanges or on the middle pipe. 8.9.10 The pipe ends in which the expansion joint is to be installed shall be perfectlyaligned or shall

8.9.11 8.9.12

8.9.13

8.9.14

8.9.15

8.10.0 8.10.1

25ES205 / 94 - R1 PAGE 16 OF 28

have specified lateral deflection as noted on the relevent drawings. The pipe ends / flanges shall be spaced at a distance specified in the drawings. The Expansion Joint shall be placed between the mating pipe ends/flanges and shall be tack welded/bolted. The mating pipes shall again be checked for correct alignment. Butt welding shall be carried out at each end of the expansion joint. For flanged Expansion Joint, the mating flange shall be bolted. After the Expansion Joint is installed the contractor shall ensure that the mating pipes and Expansion Joint are in correct alignment and that the pipes well supported and guided. The Expansion Joint shall not have any lateral deflection. The contractor shall maintain parallelism of restraining rings or bellows convolutions. INSTALLATION OF INSTRUMENTS Kinds of instrument handled 1. The following instruments shall be installed in the scope of piping installation work: a. Flow meters to be installed directly on the line (area type, volume type, magnetic type, etc.). b. Orifice flanges and orifice plates c. Displacer type or ball float type level meters d. Control / self control valves & safety valves e. Other instruments installed directly on the line

2. In addition, instruments up to the first valve or flange in the nozzle take-off connections for the instrument lead piping are included. 8.10.2 General Procedure : General installation procedure for instruments shall be as follows: a. All instruments shall be checked as to instrument number and shall be installed true to level, plumbness, or the specified angle b. The instruments and the associated piping (excluding instrument piping) shall be supported so that problems will not result due to distortion or vibration c. It is preferred to have all the instruments installed after the interior of piping, columns and drums have been cleaned. When instruments are to be installed unavoidably during piping construction, measures shall be taken to prevent the instruments from being damaged and to prevent foreign matter from entering the instruments. Orifice plates shall be installed only after testing and flushing of pipes. d. Flow control valves shall be installed after checking the flow direction mark. 8.10.3 Installation of Flow Meters : The installation of flow meters shall be as follows: a. When installing orifice flanges, the straight lengths of pipe required upstream and downstream shall be checked to see that they comply with the piping drawings. In principle, the upstream straight pipe length shall be of one piece. When there is an unavoidable welded line in the length, the distance between the orifice and the weld

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION

FABRICATION & ERECTION OF STEEL PIPING

line shall be not less than 14 times the pipe diameter. The straight lengths of pipe shall not be provided with a vent, drain, or other similar branch. b. Jack screws for orifice flanges shall be installed so that they are 180O apart from each other. c. When taps are to be taken off from a pipe, the holes shall be drilled where shown on the drawings, the burrs removed and the holes made smooth. Sockets shall not be embedded in the pipe. d. The orientation for pressure differential taps shall be accurate as shown on the drawings e. Orifice plates shall not be installed until the pipe interior has been cleaned. f. When installing orifice plates, the orifice plate number and the flow direction shall be checked. In general, the handle is pointed upwards and the inlet die stamp mark end is pointed upstream. g. An orifice plate shall be installed with its center coinciding with the center of the pipe and with the gasket not protruding into the pipe. g. An orifice plate shall be installed with its center coinciding with the center of the pipe and with the gasket not protruding into the pipe. h. Installation of flow meters such as area type, column type, and magnetic type shall be in accord ance with the instructions of the FEDO Engineer. 8.10.4 Installation of Control Valves : The installation of control valves shall be as follows: a. Control valves shall be installed by checking the flow direction and, except for special cases, with the diaphragm at the top in a vertical position. b. To prevent internal and external damage and entry of foreign matter during construction, control valves shall be installed during the last stage after pressure testing and flushing of the line. In this case, a spool having the same face-to-face dimension as the control valve shall be inserted to keep the distance during construction. Further more, after the piping around the control valve has been installed, the dimensions shall be checked to confirm that the valve can be fit in place. c. When installing control valves unavoidably during construction, a blind gasket, galvanized iron sheet, or other suitable material of the same thickness as the main gasket shall be inserted to prevent entry of foreign matter. During construction, control valves shall be covered with vinyl sheet or other suitable material, and care shall be taken not to damage the valves. During pressure testing and flushing of the line, the valve shall be removed and the end flanges of the valve shall be covered up.

25ES205 / 94 - R1 PAGE 17 OF 28

9.0.0

INSPECTION AND TEST

9.1.0

DOCUMENTS The Contractor shall submit the following inspection records for each items of test and inspection: Non-destructive inspection

9.1.1

9.1.2 9.1.3

9.2.0 9.2.1

a.

Record of radiographic inspection

b.

Record of magnetic particle inspection

c.

Record of liquid penetrant inspection

d.

Record of ultrasonic inspection

e.

Records of stress relieving

f.

Records of hardness test

g.

Records of hydrostatic & pneumatic pr. tests

Destructive inspection Record of welding procedure qualification test Others specifically instructed Following are to be indicated on the test and inspection record 1. Name of customer 2. Job number and name of work 3. Name of contractor 4. Line number 5. Date of test and inspection 6. Name(s) of attendant (FEDO, Customer, or third party) ITEMS OF INSPECTION AND TEST Prior to, during and after completion of the works, the following tests and inspections shall be performed. ITEMS FOR INSPECTION AND TEST PRIOR TO COMMENCING WORK Checking materials

Legal qualification certificate

Welding procedure test Welder’s technique qualification test

welder’s techniqe qualification certificate

Welding rod check PRIOR TO WELDING WORK Edge preparation

Angle, Root opening, Thickness of land, Cleanliness

Shape of pipe end

Out of roundness, Thickness, Uneven thickness

Bending

Degree of flattening at bent part, Radius of curvature, Thickness reduction at bent part

Tack welding

Bevelled end misalignment, Root opening

Preheating

Method of preheating, Temperature of preheating, width of heating, Temperature measurement, Heating temperature, Others

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION Welding rod

Drying temperature, Drying time

DURING WELDING WORK Welding parameters, Flow rate of sealing gas, ProtectWelding condition ing measure for welding, Condition of ambient temperature

PAGE 18 OF 28

6

Under cut No under cut is allowed for piping of cold or high temperature service.

7

Over lap

8

Height of reinforcement

Inter-layer temperature

: Within 0.8mm or 12.5% of thickness whichever smaller : 1.5mm or less

Nominal Wall Thk.

Re-examination of welder AFTER COMPLETION OF WELDING WORK Inside surface misalignment, Outer surface misalignment, Inside surface weld Visual approtrusion, Wave irregularity, pearance inspec- Uneven leg length, Irregular tion height of bead, Undercut, Overlap, Bead centre shift, Height of reinforcement welds Non-destructive inspection

25ES205 / 94 - R1

FABRICATION & ERECTION OF STEEL PIPING

Radiography, Dye penetrant, Magnetic particle

Up to 6.4mm

: 1.6mm or less

Over 6.4mm up to 12.7mm

; 3.2mm or less

over 12.7mm up to 24.5mm

: 4.0mm or less

Over 24.5mm

: 4.8mm or less

Throat thickness of fillet welds

: 70% of thickness of the inner plate or more

Stress relieving temperature and method Hardness test DURING OR AFTER COMPLETION OF WELDING WORK Product inspection

9.4.0 9.4.1

Dimension, Condition of connection to equipment, Visual apperance inspection

Non-destructive inspection Non-destructive inspection shall be performed according to the grade of inspection stipulated in the next table. (Pressure classes in accordance with ANSI B16.5) Grade of Inspection

Treatment of pipe inside Material

Thread Seal welding of threaded portion AFTER COMPLETION OF WORK Pneumatic pressure test

Carbon steel

Removal of temporary supports / scafoldings AT TRIAL OPERATION Appearance inspection

9.3.0 9.3.1

VISUAL APPEARANCE EXAMINATION Following shall be met, checking visually or in using measuring instrument 1 2

3

Inside surface : 1.5mm or less misalignment Outer surface misalignment due to difference of : 3.0mm or less diameter of thickness Inside surface weld protrusion Nominal Wall Thk. Up to 6.4mm

: 1.6mm or less

Over 6.4mm to 12.7mm

: 3.2mm or less

Over 12.7 up to 25.4mm

: 4.0mm or less

Over 25.4mm

: 4.8mm or less

4

Wave irregularity

; 2.5mm or less

5

Irregular height of bead

: 2.0mm or less

II

III

P - NO: 1

Completion of work w.r.t piping drawings Flushing

I

Pressure classes - ANSI B16.5 (psig.) Service temp. below 3500C

Less than 300 lb

400 lb 1500 lb

2500 lb and above

Service temp. 3500C or more

-

150 lb 900 lb

1500 lb and above

-

150 lb 900lb

1500 lb and above

-

150 lb 900 lb

1500 lb and above

-

150 lb 900 lb

1500 lb and above

A312 Gr. TP304

Less than 150 lb @

300 lb 600 lb

900 lb and above

Other than above

-

150 lb 300 lb

400 lb and above

Al-killed Steel P - NO: 3, 4, 5 C- 0.5 Mo Steel Cr- Mo Steel P - NO: 9 3.5 Ni steel P - NO: 8 Austenitic stainless steel

Note:

9.4.2

@ When A312 Gr. TP304 is used for cold or high temperature service, the grade II of inspection shall be applied even if it is not above 150 lb. Items of non-destructive inspection and number of samples for the random inspection shall be as follows:

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION

FABRICATION & ERECTION OF STEEL PIPING

ITEM OF INSPECTION R - Radiographic Inspection M - Magnetic particle Inspection L - Liquid PenetrantInspection Object of inspection Material

Peri phery

Nozzle (1)

Soc ket

Non pressure part

GRADE - I

R

Carbon steel

Less than 150 lb

A312 Gr. TP304

-

-

-

-

-

-

10 % (2)

10 %

10 %

10 % (4)

100 %

-

-

-

9.4.3

10 %

GRADE - II R

All materials

20 %

Carbon steel

-

M (3)

C-0.5 Mo steel Cr-Mo steel Al-killed steel 3.5-Ni steel

L (3)

Austenitic stainless steel Non-ferrous metals

GRADE - III R

All materials

M (3)

All materials except for austenitic stainless steel, non-ferrous metals & non-magnetic metal

L (3)

Austenitic Stainless steel Non-ferrous metal

% 20 % 100 % 100 % 20 (4)

Notes (1) In “nozzle welding”, welded parts of reinforcing plate and slip-on flange are included. (2) This inspection shall be performed for the welded parts other than those to which radiographic inspection was applied. (3) Either magnetic particle inspection or liquid penetrant inspection shall be performed. (4) This inspection shall be performed for Cr-Mo steel (A335 Gr. P5 or over grade) and 3.5Ni steel. Remarks 1. Radiographic inspection for peripheral joint shall be performed for pipes of nominal diameter of 2" or more having the same condition. 2. Number of random sampling test shall be at least one, when less than one is obtained in percentage of sampling 3. Number of photographs to be taken for one peripheral joint at radiographic inspection shall be as follows: PIPE SIZE NB

NO. OF PHOTOGRAPHS

50 to 80

150 x 2 sheets

100 to 150

300 x 3 sheets

9.4.4

PAGE 19 OF 28

200 to 300

300 x 4 sheets

350 to 400

300 x 5 sheets

450

300 x 6 sheets

500

300 x 7 sheets

600

300 x 8 sheets

650 & above

With film overlap of 25mm or more, no of photographs shall be equivalent to peripheral length of the pipe

3%

Over 150 lb to 300 10 % lb

25ES205 / 94 - R1

Radiographic examination Unless otherwise specified, radiographic examination shall be as follows: 1. Radiographic inspection shall be performed in accordance with Article 2, Section V of the ASME Boiler and pressure vessel code. 2. The welds to be examined shall be selected based on the number of work products of each welder and welding operator engaged in all welding operations. A minimum of one weld per sample shall be examined. 3. All welded joints in a designated lot of piping shall be radiographed over the complete circumference. 4. When a random type examination reveals a defect, additional examination shall be performed in accordance with the requirements of appendix IV. 5. The radiation source shall, in principle, be x-ray or Gama-ray. 6. Film such as Sakura RR, Fuji #100, Kodak AA, or Equivalent shall be used. 7. Identification mark as shown in Figure 10 ( Page 28 of 28 ) shall be marked on every radiograph, and radiographs of repair weld shall be marked with repair mark (R). 8. The image quality indicator (IQI) specified in B UB-51, ASME Section VIII, Division 1, or equivallent shall be used. 9. Limitations on imperfection shall be in accordance with ANSI B31.3 TABLE 327.4.1 (A) for the degree of radiography involved. Magnetic Particle/Liquid Penetrant Examination Liquid penetrant or magnatic particle examination shall be as follows: 1. Liquid penetrant inspection shall be performed in accordance with Article 6, section V of ASME Boiler and pressure vessel code. 2. Limitations on imperfection shall be in accordance with ANSI B31.3 Table 327.4.1 (A) 3. The weld surface, to which liquid penetrant or maganetic particle examination is applied, shall be finished smoothly with a grinder as necessary. 4. If a defect is found in welds, the defect shall be removed, and liquid penetrant examination or maganitic particle examination shall be performed again to confirm that no more defects exist., and then rewelding shall be performed. After rewelding has been completed, liquid penetrant examination or maganetic particle examination shall be

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION

FABRICATION & ERECTION OF STEEL PIPING

performed again to confirm that the rewelds are sound. a. Magnetic particle inspection shall be performed in accordance with Article 7, Section V of the ASME Boiler & pressure vessel code b. Limitations on imperfection shall be in accordance with ANSI B31.3 Table 327.4.1 (A)

9.5.0 9.5.1

9.5.2

9.6.0

9.6.1

9.6.2

9.6.3

HARDNESS TEST After stress relieving (SR) is performed, hardness shall be tested as follows: 1. If SR is performed by heat coil, the hardness test shall be carried out for all welds. 2. If SR is performed in furnace, hardness test shall be performed for 10% of all welds (at least one-when 10% of all is less than one) 3. Point to be tested shall be finished flat with file before the test. 4. The hardness points shall be tested to weld and to heat affected zone. Hardness test of the heat affected zone shall be made at a point as near as practicable to the edge of the weld. When dissimilar materials are welded, both heat affected zones shall be tested. Hardness limit is given in following table ( Hardness In Brinell Max. ) P-No.

MATERIAL

HB (MAX)

P-3

A335 Gr.P1 (STPA12)

225

P-4

A335 Gr.P12 (STPA22) A335 Gr. P11 (STPA23)

225

P-5

A335 Gr. P22 (STPA24) A335 Gr. P5 (STPA25)

241

PRODUCT INSPECTION Inspection for the finished product shall be performed as follows: Dimension: Right angle, perpendicularity, parallelness, dimension, etc. shall be measured visually and by measuring tools and checked against the drawings. Dimensional tolerances are as follows: 1. Length + 0 ; -3.2mm or less 2. Inclination of flange surface: less than 0.5o against the surface perpendicular to the axis of pipe. (but, not to exceed 2mm at outside circumference of flange). 3. Perpendicularity of vertical line: 2/1000 or less. 4. Horizontality: 2/1000 or less 5. Misalignment between flange center and pipe center: 1.6mm or less 6. Shift of bolt hole center: 1.0mm or less. Inspection of connection to equipment: For those pipings which are connected with pump, compressor, turbine, etc., the above dimensional tolerance shall be submitted by the tolerances required by each of such machinery. Appearance inspection: 1. Correction for jig mark.

9.7.0 9.7.1

25ES205 / 94 - R1 PAGE 20 OF 28

2. Removal of spatter and slag 3. Any harmful flaw on the flange face, inner and outer surface of pipe. 4. As-erected condition 5. Shape and size of branches and other attachment shall comply with drawings. Inspection for treatment of pipe inside Inspection shall be performed visually and touching by hand to confirm that no rust, slag, spatter, sand, or other foreign matters are left. Inspector must confirm whether sufficient flushing was performed.

10.0.0 PRESSURE TEST AND OTHERS 10.1.0 GENERAL 10.1.1 Prior to initial operation, the installed piping shall be pressure tested under witness of FEDO Engineer/ Representative. 10.1.2 Prior to the pressure test, a line check shall be performed based on P&I diagrams and the piping draw ings, in accordance with the instructions of the FEDO Engineer/ Representative. 10.1.3 Types of pressure test are as follows, however the test shall be performed in accordance with the individual specification: 1. Pressure tests Hydraulic test (using water or other liquids) Pneumatic test 2. Leak test Overall air tightness test 10.1.4 Before filling it with the test fluid, the entire line to be pressure tested shall be examined in the manner described in Section 9.0.0, and any faults shall be repaired. The piping affected by any repairs or additions made after the pressure test shall be retested. 10.1.5 In principle, piping shall be pressure tested at a metal temperature not less than 20C. However, carbon and alloy-steel piping exceeding 25mm in thickness shall be pressure tested at a temperature not less than 160C. 10.1.6 The following equipment and instruments shall not be connected to the piping before completion of the pressure test: 1. Rotating machinery such as pumps, turbines, and compressors. 2. Pressure relieving devices, such as rupture discs and pressure relief valves. 3. Equipment that has a castable or lining material . 4. Instruments. 5. Piping which is normally open to the atmosphere such as drains, vents, and discharge piping from pressure relieving devices. 6. Any other designated equipment. 10.2.0 TEST FLUID Test fluid shall be as follows: 10.2.1 In principle, the fluid for hydrostatic testing shall be fresh water. Unless otherwise specified, the

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION

10.2.2

10.2.3

10.3.0

10.3.1

10.3.2

10.3.3

10.3.4

10.3.5

10.4.0 10.4.1

chlorine ion concentration in the fluid used for austenitic stainless steel piping shall not exceed 30 ppm. After completion of the test, the water shall be drained immediately, and the interior of the pipe shall be dried by an air blower, etc. For piping systems having strong acids and So2 where water may become corrosive, or piping systems operated at a temperature of 00C or less, kerosene or similar light oils (with a flash point not less than 500C) or air is preferred as the test fluid. The air to be used for pneumatic testing shall be compressed air from a portable compressor. However, for instrument air lines or where specifically specified, oil-free dry compressed air or inert gas shall be used. For high pressure piping (not less than 100 kgf/cm2G), the use of inert gas is preferable. When pneumatic testing is performed by the use of an air compressor, precautions against combustion shall be taken by blowing clean the oil separator thoroughly so that no lubricant enters the air. TEST PREPARATION The preparation for pressure test shall be as follows: All joints (including welds) are to be left uninsulated and exposed for examination during the test. However, joints previously tested in accordance with this standard may be insulated. When filling water into piping that is designated for vapor, gas, etc., not filled with water during operation, temporary supports or other reinforcements shall be provided beforehand. Special fittings in piping components, such as expansion joints, filters, and flame arrestors, shall be disconnected from the piping. Equipment which is not to be subjected to the pressure test shall be either disconnected from the piping or isolated by blinds or other means during the test. If a pressure test is to be maintained for a certain period and the test liquid in the system is subject to thermal expansion, precautions shall be taken to avoid excessive pressure. In particu lar, for hydrostatic testing, care shall be taken to ensure that the water will not be subject to thermal expansion so that the piping is not damaged during the test. TEST PRESSURE Hydraulic Testing of Internally Pressured Piping 1. The test pressure for piping subject to internal pressure shall be as follows: b. For a design temperature above the test temperature, the minimum test pressure shall be calculated by the following formula. 1.5PST S

ST= allowable stress in kgf/cm2 at test temperature S = allowable stress in kgf/cm2 at design temperature

10.4.2

10.4.3

10.4.4

10.5.0

10.5.1

10.5.2

Where PT= minimum hydrostatic pressure in kgf/cm2 G

PAGE 21 OF 28 P = internal design pressure in kgf/cm2 G

a. Not less than 1.5 times design pressure

PT =

25ES205 / 94 - R1

FABRICATION & ERECTION OF STEEL PIPING

10.5.3

3. If the test pressure as defined in Item (2) above produces a stress in excess of the yield strength at the test temperature, the test pressure may be reduced to the maximum pressure that will not exceed the yield strength at test temperature. Hydrostatic testing piping with vessels as a system 1. Where the test pressure of piping attached to a vessel is the same as or less than the test pressure for the vessel, the piping may be tested with the vessel at the test pressure of the piping. However, the test pressure shall be controlled carefully so as not to exceed the test pressure of the vessel. 2. Where the test pressure of piping exceeds the vessel test pressure, the piping shall be tested by isolating it from the vessel. Hydrostatic testing of externally pressured piping : The test pressure for piping subjected to external pressure shall be as follows: a. Lines in external pressure service shall be subjected to an internal test pressure of 1.5 times the external differential design pressure, but not less than a pressure of1.0 kg/cm2G (15 psig). b. In jacketed lines, the internal line shall be pressure tested on the basis of the internal or external design pressure, which ever is critical. The jacket shall be pressure tested on the basis of the jacket design pressure unless otherwise specified. Pneumatic testing 1. In principle, pressure tests shall be performed hydraulically, however, when it is inappropriate to fill piping with water, the test may be performed with air or inert gas. The test pressure shall be 1.1 times the design pressure. 2. Any pneumatic test shall include a preliminary check at not more than 1.75 kgf / cm2G (25 psig) pressure. The pressure shall be increased gradually in steps providing sufficient time to check for leaks. TESTING METHOD The method of pressure testing shall be in accordance with the instructions of FEDO. However, the general method by using water shall be as follows: In principle, pressure tests shall be performed for each piping system. However, when design conditions do not permit testing in such a manner, the system may be tested in sections. Test blinds shall have a handle extending out from the flange. The handle shall be painted in red, to ensure removal of blind after testing. Installation and removal of blinds shall be performed in accordance with the instructions of

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION

25ES205 / 94 - R1

FABRICATION & ERECTION OF STEEL PIPING

FEDO. The number or all the blinds used and the location of the insertion shall be recorded at all times. 10.5.4 Test pressure gauges with graduations up to two times the prescribed test pressure shall be provided. All the pressure gauges shall be certified by the national authority, and the calibrations shall be checked by periodic inspections. 10.5.5 Two or more pressure gauges shall be installed so that they are easily observed. When the piping system to be tested extends from a low to a high level, pressure gauges shall be installed at both the lowest and the highest points. 10.5.6 For each piping system, an outlet for discharging the pressure in case of emergency shall be designated and marked to that effect. 10.5.7 During pressure testing of piping, operation of valves shall be prohibited and the valves shall be marked to that effect. 10.5.8 Prior to pressure testing, it shall be confirmed that a strainer is provided at a designated location to remove foreign matter. 10.5.9 Vents on piping subjected to hydrostatic testing shall be opened to remove the air when filling the piping with water. 10.5.10 Prior to hydrostatic testing, the piping shall be checked to confirm that it is free from air pockets and if necessary, temporary vents shall be provided to eliminate the air pockets until testing is completed. 10.5.11 For piping systems with a check valve, the pressure shall be applied from upstream of the valve. If this is impractical, the check valve shall either be reversed or shut off with blinds. However, when reversed, the valve shall be reinstalled correctly after testing. 10.5.12 When the test pressure is not less than 50 kgf / cm2G, pressure shall be increased gradually. 10.5.13 The test pressure during a pressure increase shall be read by the pressure gauge installed at the lowest point of the piping in consideration of the water head pressure. 10.5.14 The check for any leaks during the pressure test shall be performed after the prescribed pressure is maintained for a time not less than 10 minutes. All connections and all welded joints shall be inspected thoroughly. 10.5.15 After the completion of pressure testing, the water shall be drained immediately from the line to prevent the piping system from being damaged by freezing or thermal expansion. Also to prevent vacuum forming in the piping, the vents shall be opened when the water is being drained. 10.5.16 On completion of pressure testing, the line shall be checked to see that no residual pressure is present, and the line shall be drained. All blinds shall be removed. 10.5.17 Short pieces of pipe, which must be removed for installing blind plates and blind flanges, shall be tested separately. 10.5.18 All valves, orifice plates, expansion joints, short pieces of pipe, and other items removed or installed for the test, shall be reinstalled with the prescribed gaskets in the correct position.

PAGE 22 OF 28

10.6.0 REPAIR OF DEFECTS The repair of defects found during test and inspection of piping systems shall be as follows. In principle, the repair shall be performed under witness of FEDO after the approval of the FEDO Engineer has been given. 10.6.1 Repair of welds a. Repair welding shall be performed after the pressure and liquid remaining in the pipe have been removed. b. The defects to be repair welded shall be removed completley with a grinder, etc. c. The welding, the heat treatment, and the test and inspection shall be the same as required for the initial welding, and performed in accordance with the applicable provisions of this specification. d. In principle, repair welding of the same portion shall not be performed more than twice. 10.6.2 Repair of Threaded Joints All defective threaded joints shall be replaced with complete new ones. 10.6.3 Repair of Flange Joints All defective flange joints shall be replaced with complete new ones, except those which can be repaired in accordance with Section 5.2 (15). 10.7.0 FLUSHING AND CLEANING 10.7.1 Selection of cleaning method Cleaning method shall be selected in the following methods considering kind of fluid, pipe material and condition of internal surface of piping to be cleaned. Cleaning method and extend of cleaning shall be as per specific Project Requirements. a. b. c. d. e. f.

Water Flushing Air Blowing Steam Blowing Acid Cleaning Oil Cleaning Others

10.7.2 Procedure of cleaning in general 1. Cleaning of fabricated pipings Inside surface and face of weld of fabricated piping shall be made free from slag, chamfer, scale and other foreign matter, with grinder, chisel, wire brush, etc., and be airblown. After completion of air blowing and checking, ends of the piping shall be covered with vinyl or veneer cap, etc. till the installation in the field. 2. Temporary Strainers Temporary strainers shall be used as follows: a.

After installation of piping, and before commencement of flushing/cleaning.

b.

The temporary strainers shall be installed at pump suction piping, upstream of control valve and other locations as specified.

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION

FABRICATION & ERECTION OF STEEL PIPING

c.

Mark plate shall be attached to the temporary strainers to distinguish from other strainers.

d.

After a constant period of initial operation, all temporary strainers shall be removed, cleaned and reinstalled.

10.8.0 WATER FLUSHING 10.8.1 Cleaning method by water 1. As a rule, pure water, service water, steam condensate, industrial water, etc. shall be used. If there is any requirement about the quality of water to be used, it shall be observed. 2. After flushing, drying by compressed air or natural drying shall be carried out. Drying by superheated steam shall be carried out with agreement between Customer and FEDO. 3. Flushing shall be performed till the water becomes free from foreign matter, scale, etc. This shall be decided by observing turbidity of water taken out ( into beaker or cup). 4. Water flushing shall be performed by the method of running by pressurised water and hammering, or rapid draining with water filled. Hammering shall, however, not be performed for austenitic stainless steel pipe, copper pipe, aluminum pipe. 5. The primary cleaning shall be performed for each assembled piping system including the equipment. 6. Where instruments are included in piping system to be cleaned, the instruments shall, as a rule, be disconnected and spool pipe (distance piece) shall be inserted instead. 7. When cleaning is carried out in the condition that control valve is connected, the procedure shall be as follows: a. Disconnect companion flange at upstream side of the control valve and cover opening of the control valve. b. Clean the piping of upstream side. c. Connect the control valve and the piping of upstream side after cleaning. d. Close the control valve, open by-pass valve, and then clean the piping of down stream side. Where the by-pass valve is not installed, the temperory strainer having austenitic stainless steel screen of No. 50 specified in ASTM E-11 shall be inserted.

10.8.2 Air blowing 1. Air blowing shall be performed by the method of blowing by pressurized air and hammering. Hammering shall, however, not be performed for austenitic stainless steel pipe, copper pipe and aluminum pipe. 2. Blowing shall be performed till there remains no scale in the piping. FEDO personnel in charge shall make judgement of whether the result of the cleaning is statis-

25ES205 / 94 - R1 PAGE 23 OF 28

factory or not 3. The primary cleaning shall be performed for each assembled piping. The secondary cleaning shall, as a rule, be performed for piping from eqpt. to adjacent eqpt. Whether or not the equipment is included shall be determined considering shape, internal construction & packing of the eqpt. and according to overall cleaning planning. 10.8.3 Steam blowing 1. Execution of steam blowing Steam blowing shall be executed after completion of pressure test and insulation work. 2. Preparation of steam blowing a. Temporary piping work, countermeasure for safety & confirmation of preparation shall be done according to blowing plan. b. Support shall be attached to exhaust piping to prevent accident caused by the reaction force during blowing.

3. Procedure of steam blowing a. Warm up the piping with cooperation by operator b. Check expansion joints, spring hangers, etc., for expected thermal expansion. c. Steam blowing shall be performed at the temperature near to the operating temperature, considering operating condition of boiler. d. To remove the scale effectively by temperature change, it is required to perform flushing and cooling cyclically, having temperature difference as large as possible between the flushing and cooling.

4. Judgement criteria of steam blowing a. Judgement on result of steam blowing shall generally be done by checking color or quantity of foreign material present in the drain sampled. b. If necessary, especially for suction line of steam turbine etc., result of flushing shall be judged by observing whether scratch was produced or not on the test piece inserted in the line.

10.8.4 Acid cleaning 1. Applicable piping of acid cleaning Unless otherwise specified in specific job requirements, acid cleaning shall apply to oil piping system of rotating machinery. 2. Cleaning method by acid As a rule, acid cleaning procedure shall be as follows:

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION

25ES205 / 94 - R1

FABRICATION & ERECTION OF STEEL PIPING

a. Ten-percent hydrochloric acid solution or Ten-percent sulphuric acid solution with temperature 30 to 400 C shall be used, and piping shall be pickled in the acid solution for 1 to 6 hours. b. After pickling, the piping shall be washed sufficiently to remove the acid solution by water. c. And the piping shall be rinsed for neutralization of the acid solution by sodium hydroxide solution, followed by water flushing. d. The piping shall be well dried by superhaeted steam or dry air and the inside of pipes given a coat of the oil of the same quality as specified to be used in the oil piping.

Remarks: Oil piping of stainless steel shall not be acid cleaned. 10.8.5 Oil cleaning 1. Applicable piping of oil cleaning Oil cleaning shall apply to the oil piping system after the acid cleaning specified in par. 10.8.4 has been performed. 2. Cleaning method by oil The procedure shall be as follows:

PAGE 24 OF 28

10.10.0Disposition 10.10.1All construction equipment used for the piping work, and all surplus, scrap and debris shall be disposed of in accordance with the instructions of the FEDO Engineer. 10.11.0 Test record 10.11.1 All inspection and test results shall be made into re cords in accordance with the instructions of FEDO. The records shall be submitted for approval to FEDO.

11.0.0 APPENDICES 11.1.0 The following Appendices shall form a part of this manual: TITLE

REFER TO:

Grove face Rust Preventive

APPENDIX I

Selection of welding electrodes

APPENDIX II

Procedure for Flange Bolt up

APPENDIX III

Additional Random Type Examination for weld defects

APPENDIX IV

a. Oil to be used shall have good quality suitable for the machinery, and shall be completly replaced with the specified oil after cleaning. b. The cleaning shall be performed by the method of circulation of the oil and hammering. Hammering shall, not be performed for copper pipe. c. After completion of cleaning, it shall be checked that no foreign matter is present in temporary strainer screen of No.200 specified in ASTM E- 11 for oil pipings of centrifugal compressor, and screen of No.100 specified in ASTM E-11 for other oil pipings.

10.8.6 Other cleaning method 1. Cleaning method by pig or cushion ball Cleaning by the use of pig or cushion ball shall confirm to specific job requirements. 2. Cleaning method by sodium hydroxide Cleaning by sodium hydroxide solution shall conform to specific job requirements. 3. Special cleaning Special Cleaning, if specified for special piping components or systems, shall conform to specific job requirements. 10.9.0 Overall airtightness test 10.9.1 When specified, an overall airtightness test shall be performed for the piping of process line by the use of air or inert gas after completion of flushing.

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION

FABRICATION & ERECTION OF STEEL PIPING

APPENDIX — I GROOVE FACE RUST PREVENTIVE Features of Product 1. As rust preventive applied to the groove face, in general, deoxialuminite is used as it is not detrimental to the weld. Deoxialuminite is the brand name of a product of Special Chemical Co., Ltd.of USA. This was first produced in Japan by Nippon Oil & Fats Co., Ltd. and is sold under the brand name of Tasteto Silver. 2. The composition of the product is 40% resin, 50% solvent, 5% pigment, etc., and the percentage of resin in the compound is high to reduce the amount of gas produced during welding. 3. This product is recommended for both marine and overland transportation. The thickness of the applied product shall not be more than 30 microns. 4. The adherent durability is not more than three months. Directions for Use 5. Before applying the rust preventive, it shall be confirmed that the groove face is clean. 6. After the rust preventive has been applied, welding shall not be performed within two weeks. 7. In principle, the application shall be sprayed by maintaining a distance not less than 30 cm from the spray nozzle to the object. Unless otherwise specified, the product shall not be applied with a brush.

25ES205 / 94 - R1 PAGE 25 OF 28

Procedure for Bolt Up Procedure for flange bolt up shall be as follows 5. Hand tighten bolts with a short wrench by the procedure shown in Figure 11. 6. Tighten bolts a second time with a spanner wrench and light hammer (about 1 kg), again by the procedure shown in Figure 11. 7. Continue tightening gradually by the procedure shown in Figure 11, using a heavy hammer (about 2 kg) until bolts are completely drawn tight. This may take two or three additional rounds by the same procedure. 8. For bolts larger than 25mm in diameter, a final round or two with a heavier hammer (about 3.5 kg) is recommended to reach the correct bolt tension. Precautions Special precautions shall be taken for the following items for bolt up: 9. Never draw up tight on one or two bolts only. This will cause local gasket crushing or pinching, which will result in leaks. 10. After each round of tightening, the alignment may be checked by measuring the distance between flange faces. 11. The bolts should be gradually and evenly tightened with a wrench and hammer until the hammer begins to “bounce” with a distinct ring.

APPENDIX — IV APPENDIX — II SELECTION OF WELDING ELECTRODES & RODS Table - I : Selection of welding electrodes & rods for joining similar materials except Aluminium Table - II : Selection of welding electrodes & rods for joining disimilar materials except Aluminium

( Tables overleaf )

APPENDIX — III PROCEDURE FOR FLANGE BOLT UP Confirmation Prior to Bolt Up The following items shall be confirmed prior to bolt up: 1. The gasket has been inserted and centered. 2. Bolts and nuts have been lubricated. 3. Bolts have been inserted and are finger tight. 4. There are at least two threads extending beyond the nut on either side.

ADDITIONAL RANDOM TYPE EXAMINATION FOR WELD DEFECTS (Taken from ANSI / ASME B31.3b-1982, 336.5) When the required examination of a spot or random type reveals a defect requiring repair, two additional examinations of the same type shall be made on the same kind of item (if of a weld, others by the same welder or welding operator). If the second group of items examined is acceptable, all items represented by these additional examinations shall be accepted. For each of the second group of items which reveals defects requiring repair, two additional items shall be examined. If all of the third groups of items examined are acceptable, the items requiring repair shall be repaired or replaced to meet the requirements of the code, and all items represented by the examined items shall be accepted. If any of the third group of items examined reveal defects requiring repair, all comparable items may be replaced or they shall fully examined and repaired as necessary to meet applicable quality requirements.

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION

25ES205 / 94 - R1

FABRICATION & ERECTION OF STEEL PIPING

PAGE 26 OF 28

TABLE - I : SELECTION OF WELDING ELECTRODES & RODS FOR SIMILAR MATERIALS EXCEPT ALUMINIUM MATL.

BASE MATERIAL

NO. 1 2

AWS SPEC.

CLASSIFICATION

E6010/E6013 (1)

(2) (3) (4)

—

UTS 60,000psi & above

A 5.1

E6010/ E7018 (1)

(2) (3) (4)

—

A333 Gr - 1

A 5.1

E7018 -1(5)

(5)

--

A 5.5

E70XX-A1

(2) (3) (4)

—

2a 3

carbon-molybdenum 1

AWS SPEC PREFERRED ELECTRODE

WELDING RODS

A 5.1

UTS UNDER 60,000psi carbon steel

COVERED ELECTRODES

4

2 /4 nickel

A 5.5

E80XXC1

(2)

—

5

31/2 nickel

A 5.5

E80XX-C2

(2)

—

6

9 nickel

A 5.11

ENi Cr Fe - 3

A5.14

ER Ni Cr -3

7

1

/2Cr–1/2Mo

A 5.5

E8015-B2L

(2)

0.05C max.

8

1

1Cr– /2Mo

A 5.5

E8015-B2L

(2)

0.05C max.

9

11/4Cr–1/2Mo

A 5.5

E8015-B2L

(2)

0.05C max.

2 /4Cr–1Mo

A 5.5

E9015-B3L (0.05C max.)

(2)

0.05C max.

1

5Cr– /2Mo

A 5.4

E502-I5 (0.05C max.)

A5.9

ER502(0.05C max)

7Cr–1/2Mo

A 5.4

E7Cr-I5 (0.05C max.)

(2)

(0.05C max.)

10 11

low chromium ferrtic steels

12

1

13

9Cr–1Mo

A 5.4

E505-I5 (0.05C max.)

A5.9

ER505(0.05C max)

14

AISI Type405

A 5.4

E410-I5 (0.05C max.)

A5.9

ER410(0.05C max)

AISI Type 410S

A 5.4

E410-I5 (0.05C max.)

A5.9

ER410(0.05Cmax)

15 16

ferrtic stainless steels

AISI Type410

A 5.4

E410-I5 (0.05C max.)

A5.9

ER410(0.05C max)

17

AISI Type430

A 5.4

E430-I5

A5.9

ER430

18

AISI Types 304&304H

A 5.4

E308-I5 or 16

A5.9

ER308

19

AISI Type 304L

A 5.4

E308L-I5 or 16

A5.9

ER308L

20

AISI Types321&321H

A 5.4

E347-I5 or 16

A5.9

ER347

AISI Types 347 & 347H

A 5.4

E347-I5 or 16

A5.9

ER347

AISI Types 316 & 316H

A 5.4

E316-I5 or E 16 -8 -2

A5.9

ER316

AISI Type 316L

A 5.4

E316L-I5 or 16

A5.9

ER316L

AISI Type309

A 5.4

E309-I5 or 16

A5.9

ER309

21 22 23

austenitic stainless steels

24 25

AISI Type310

A 5.4

E310-I5 or 16

A5.9

ER310

26

Incoloy(32Ni46Fe20Cr)

A 5.11

ENi Cr Fe-2

A5.14

ERNiCr -3

27

AluminiumBronze

A 5.6

ECu Al-A1

A5.7

RCu Al-A2

28

Phosphor Bronze

A 5.6

ECuSn-C

A5.7

RCuSn-A

29

Copper

A 5.6

ECu

A5.7

RCu

30 31 32

non– ferrous metals & alloys

67Ni-30Cu Monel

A 5.11

ENiCu-4

A5.14

ERNiCu-7

Hastalloy(60Ni-28Mo-5Fe)

A 5.11

ENiMo - 1

A5.14

ERNiMo-4

Inconel(75Ni 15Cr8Fe)

A 5.11

ENiCrFe -1

A5.14

ERNiCrFe-5

33

70Cu-30Ni

A 5.6

ECuNi

A5.7

RCuNi

34

Nickel

A 5.11

ENi-1

A5.14

ERNi-3

35

20Cr-29Ni-21/2Mo-3Cu

-

Alloy 20 Cb - 3

—

Alloy 20Cb3

Notes: (1) For materials Nos.1 and 2 (Carbon steel) where SMAW is followed, the root run shall be with E 6010 electrodes. (2) Where no AWS specification exists for base wire, it is acceptable to use wire or rods of the same nominal composition as the base material with substantially neutral flux or inert gas, provided they have been qualified in the procedure test. (3) MIG wire shall conform to AWS A5.18 and A5.20 (4) SAW wire and flux shall conform to AWS A5.17 (5) The root run of butt welds for material No. 2a shall be made in GTAW process using ER70S - 2 wires.

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION

25ES205 / 94 - R1

FABRICATION & ERECTION OF STEEL PIPING

PAGE 27 OF 28

TABLE II — SELECTION OF WELDING ELECTRODES & RODS FOR WELDING DISSIMILAR MATERIALS EXCEPT ALUMINIUM Lower base mat’l No.

2

3

4

5

6

7

8

9

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 35

1

A

A

A

A

A

B

B

B

B

B

B

B

B

B

B

B

C

C

C

C

C

C

D

D

E

C

2 3 4 5 6 7 8 9

Higher base material number

A

A

A

A

B

B

B

B

B

B

B

B

B

B

B

C

C

C

C

C

C

D

D

E

C

@

@

@

B

B

B

B

B

B

B

B

B

B

B

C

C

C

C

C

C

D

D

E

C

A

A

@

@

@

@

@

@

@

@

@

@

@

C

C

C

C

C

C

D

D

E

@

A

@

@

@

@

@

@

@

@

@

@

@

C

C

C

C

C

C

D

@

E

@

@

@

@

@

@

@

@

@

@

@

@

E

E

E

E

E

E

E

@

E

@

A

A

A

A

A

A

A

A

A

A

C

C

C

C

C

C

D

E

C

@

A

A

A

A

A

A

A

A

A

C

C

C

C

C

C

D

E

C

@

A

A

A

A

A

A

A

A

C

C

C

C

C

C

D

E

C

@

A

A

A

A

A

A

A

C

C

C

C

C

C

D

E

C

@

A

A

A

A

A

A

C

C

C

C

C

C

D

E

C

@

10 11 12

A

13

A

A

A

A

C

C

C

C

C

C

D

E

@

@

A

A

A

A

C

C

C

C

C

C

D

E

@

@

A

A

A

C

C

C

C

C

C

D

E

@

@

A

A

C

C

C

C

C

C

D

E

@

@

A

C

C

C

C

C

C

D

E

@

@

C

C

C

C

C

C

D

E

@

@

A

A

A

A

A

A

A

A

C

F

F

A

F

F

F

C

A

A

A

A

A

A

C

A

A

A

A

A

C

A

A

A

A

C

A

A

A

C

C

E

C

E

C

14 15 16 17 18 19

F

20 21 22 23 24 25 26

C

DESCRIPTION OF CODE LETTERS IN ABOVE TABLE A

As specified in table I for material corresponding to either the higher or lower base material number

B

ASME SFA-5.5, E8015-82L electrode

C

ASME SFA-5.4, E309 electrode. Acceptable alternatives shall be as specified in table I for the higher base material number

D

As specify in table I for the material with the higher base material number

E

ASME SFA-5.11, ENiCrFe-2 electrode and ASME SFA-5.4. ERNiCr-3 rods shall be used where design temperature exceeds 10000F (5380C). ASME SFA-5.4, E310 electrodes are to be used where service temperatures are below 10000F (5380C) and expected to be relatively constant after start up. All rods, excluding alternatives shall require written approval from designated authority.

F

ASME SFA-5.4, E308 electrode or as specified in table I for the material with the higher base material number

@

Welding of these material combinations are not permitted without written approval from designated authority.

FACT ENGINEERING AND DESIGN ORGANISATION

8122-03-ES-001 Page 1 of 4 Specification for Glass Reinforced Plastic (GRP) piping 1

Scope This specification defines the requirements for glass-fiber-reinforced thermosetting resin pipe (RTRP) as defined in AWWA C950) couplings, fittings, flanges and spools using polyester, vinyl ester or epoxy resin with restrained adhesive-bonded joints, restrained gasketed joints, butt joints with laminated overlay, bell & spigot joints with laminated overlay. The minimum pressure/temperature rating of the pipe and fittings shall be 10 bar (150 psig) at 65 deg C

2

Materials and Fabrication The products shall be defined by a cell classification system and shall meet the performance requirements of Section 4 of this specification. Pipe and couplings shall be filament-wound using polyester, vinylester or epoxy resin and fiberglass reinforcement or centrifugally cast. Resin System Resin shall be suitable for the services specified, and shall be noted by the vendor in his proposal. The resin system used for the interior liner, the structural wall, fittings, and adhesives shall be polyester, vinylester or epoxy, with suitable curing agents so that it meets the performance requirements and temperature limits in this Specification. Glass Reinforcements The structural wall reinforcement shall be of commercial-grade glass fiber ( E type) treated with a compatible binder and coupling agent Additives Resin additives such as pigments, dyes or coloring agents may be used, provided they do not detrimentally affect the performance of the pipe. The pipe exterior must contain a UV inhibitor. Reinforcing Fiberglass Ribs Pipe sizes 2600 mm and higher can be manufactured with reinforcing fiberglass external ribs to achieve the required stiffness. Adhesives and solvent cleaners Adhesive and solvent cleaner for bonded joints shall be of a material suitable for the services and design conditions specified. It shall be mutually compatible with the resin used to manufacture the pipe. Adhesives and solvent cleaners shall be provided in a self-contained kit with all necessary materials and instructions. Shelf life of adhesive and solvent cleaner kits, at 35 deg C, shall not be less than 9 months from the date of shipment. Adhesive and solvent cleaner kits shall indicate the required storage conditions and date of expiration of shelf life. Flexible Elastomeric Seals and Joint Tightness The chemical composition of the flexible elastomeric seals shall be compatible with the type of service and environment to which it will be subjected. Fittings Flanges, bends, reducers, tees, wyes and other fittings may be compression-molded, manufactured from mitered section of pipe, or manufactured by the filament wound process, using thermosetting polyester, vinylester or epoxy resin and fiberglass reinforcement such that the resistance to chemical attack, the pressure rating, and the temperature rating, are equal to or better than that of the pipe. Except for compression-molded fittings, all pipe, fitting, and flange surfaces that are exposed to the fluid shall have a smooth, uniform, resin-rich liner. The interior liner shall be reinforced with either non-woven polyester fibers or epoxy. Liner reinforcement is not required on 100 mm and smaller fittings at the mitered joints, provided all gaps at the joints are completely filled with resin to act as an effective corrosion barrier and to prevent the presence of any exposed glass fibers.

8122-03-ES-001 Page 2 of 4 All machined or cut surfaces shall be post-coated with catalyzed resin, except for bonding surfaces for field points and mechanical RTR (fiberglass) threads. Post-coating shall be performed within four hours of machining or other surface preparation. Adhesive-bonded joints shall be bell-and-spigot type and shall not require a field-applied overwrap to develop the required strength. Flanges shall be flat-faced, or flat-faced with a confined O-ring gasket groove. All pipe, fittings and flanges for a particular installation shall be manufactured or supplied by the same Vendor to avoid incompatibility problems Fasteners and Gaskets Machine bolts shall be as per A307 Gr B, galvanised and nuts shall be as per A563 Gr B galvanised. The gaskets shall be full face, non metallic as per B16.21. suitable for the fluid. 3

Dimensions and Tolerances Dimensions and surface finishes shall be measured in accordance with ASTM D3567 and ASME/ANSI B46.1. The average wall thickness of the pipe shall not be less than the nominal wall thickness published in the manufacturer literature. The minimum wall thickness at any point shall not be less than 87.5% of the nominal wall thickness, when measured in accordance with ASTM D3567. Flange bolt hole sizes and the number of bolt holes and bolt hole circles for up to 600 mm nominal pipe size shall comply with ASME/ANSI B16.5. For larger than 600 mm nominal pipe size, flange bolt holes sizes and the number of bolt holes and bolt hole circles shall comply with AWWA C207, or MSS SP-44. Unless otherwise defined in the Purchase Order, specified face-to-face, centerline-to-face, and centerline-to-centerline dimensions of special fabrications (spools) shall have a tolerance of + 6 mm. The lateral offset of flanges from the pipe centerline and rotation of flanges shall be limited to 3 mm. The flange face alignment shall be within 1.5 mm of the required position when measured across the flange face. These tolerances shall be doubled for piping 450 mm nominal size and larger.

4

Performance Requirements General The Manufacturer shall perform following Design Type tests and Test reports shall be furnished to Buyer.Testing and test reports shall pertain to items representative of those supplied under the Purchase Order. Design type testing shall be repeated after any change in materials, manufacturing methods, or product design. Design Type Tests Hydrostatic Design Stress and Pressure Ratings The long-term hydrostatic strength of pipe shall be determined in accordance with Procedure A or B of ASTM D2992. The Manufacturer shall select the procedure and one representative size for these tests. Adhesive joints shall be included, using both the factory and field adhesives and their respective joining and curing procedures, if different. Pressure rating calculations shall be performed in accordance with AWWA-C950. The calculated pressure ratings shall equal or exceed the pressure rating of the piping specified in section 1 of this specification and in the Purchase Order. Long-Term Ring Bending Strength Long-term ring bending strength shall be determined in accordance with AWWA C950, with stress relaxation or creep failure tests instrumented to detect an abrupt, significant reduction in mechanical properties. Flange Pressure Rating Flanges shall be pressure-rated and marked in accordance with ASTM D4024. The manufacturer shall test, on a one-time basis, three samples of minimum, median and maximum flange sizes of the manufacturing range at the plant for each pressure rating.

8122-03-ES-001 Page 3 of 4 Joint Integrity Test Joints shall be of the adhesive-bonded, reinforced overlays or mechanical type joints, as defined in AWWA C950. The joints shall meet or exceed the hoop tensile and axial tensile strength requirements of the pipe as tested in accordance with AWWA C950. One test for each jointing method shall be performed to establish design stress values. 5

Test Requirements Pipe Stiffness The pipe stiffness shall be determined in accordance with AWWA C950. The pipe shall exhibit, without structural damage, the minimum stiffness at 5 percent deflection of 124 kPa (18 psi) Axial Tensile Strength The pipe shall be sampled and tested for axial tensile strength in accordance with AWWA C950. The test results shall meet or exceed the minimum axial tensile strength requirements listed in Table 11 of AWWA C950 Hoop Tensile Strength The pipe shall be sampled and tested for hoop tensile strength in accordance with AWWA C950. The test results shall meet or exceed the minimum hoop tensile strength requirements listed in Table 10 of AWWA C950 Visual Inspection Components shall be visually inspected for compliance with the defect limits in Table below Name 1. Air Bubble (Void)

2. Foreign Inclusion

3. Pit (Pinhole) 5. Scratch 6. Wrinkle

Interior Surface Not to penetrate any surface - limits apply to all surfaces, maximum dimension 6 mm diameter, 0.75 mm thickness, 4 per 0.09 sq. m area Not to penetrate any surface - limits apply to all surfaces, maximum dimension 1.5 mm, 1 per 0.09 sq. m area Max. depth 0.25 mm, maximum width 1.5 mm, 35 per sq. cm Max. depth 0.40 mm not to exceed liner thickness Max. depth 2 mm

Exterior Surface Same requirements as for Interior Surface

O-Ring Sealing Surface Same requirements as for Interior Surface

Same requirements as for Interior Surface

Same requirements as for Interior Surface

Not to penetrate reinforced wall

Maximum dimension 0.25 mm

Not to penetrate reinforced wall Not applicable

Maximum depth 0.25 mm None allowed

Hydrostatic Leak Test All pipe, fittings and spools shall be hydrostatically leak tested at the factory in accordance with AWWA C950, to a test pressure equal to twice the pressure rating. If air is used as the pressurizing medium, the component shall be completely submerged in clear water during the pressurization and inspection period. All pipe, fittings, spools and joints shall be visually examined for leakage. Any item showing evidence of weeping or leakage shall be rejected.

8122-03-ES-001 Page 4 of 4 The standard adhesive-bonded flanges, standard adapters, saddles, nonstandard fittings with plain ends configurations, and prefabricated spools with plain ends that cannot be hydrotested at the manufacturing facility due to size limitations and configurations shall be handled as follows: a)

The Vendor shall mark these items to be field hydrotested.

b)

The assembled items and the testing shall be at Vendor's risk.

c)

Buyer's Representative shall witness the test. The rejected parts shall be removed from the system or repaired by the. The replaced or repaired part shall be retested. Rejection If the results of any QC test do not conform to the requirements of this specification, that test shall be repeated on two additional samples from the same lot of pipe. Each of the two samples shall conform to the requirements specified. If either of the two additional samples fail, the lot shall be rejected.

6

Documentation Drawings Product drawings that show product dimensions and tolerances, including couplings, fittings and joints, shall be submitted Test Reports The Manufacturer's test reports, both Design Type tests and acceptance tests, shall be furnished to the Buyer.

7

Identification Tagging All components shall be permanently marked for proper identification. All required marking shall remain legible under normal handling and installation practices. The marking shall include the following: -

8

Manufacturer's name or trade name, and identification code Pressure/temperature rating Nominal diameter Packing Unless otherwise specified in the Purchase Order, pipe, fittings, O-rings, gaskets, locking rings, and adhesives shall be packed suitably, to withstand rough handling. End Protectors End protectors shall be provided and securely attached to both bell and spigot ends of all pipe. End protectors shall be designed to protect the pipe ends from impact damage, contamination, and weathering of machined bonding surfaces due to ultraviolet exposure. They shall have an open center permitting inspection of the pipe bore. Flange faces on fabricated piping shall have 12 mm minimum protective plywood covers not smaller than the flange outside diameter

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MANGALORE LPG BLENDING FACILITIES

SPECIFICATION FOR PIPELINE CONCRETE COATING

PREPARED FOR

HPCL

PROJECT NO. 8122

OCTOBER 2009

0

19.10.2009

LTA

SA

SA

REV.

DATE

PRPD. BY

CHKD. BY

APPRD. BY

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TABLE OF CONTENTS

PAGE O.

FACT 12FT026A/94

1.0

SCOPE

3

2.0

REFERENCE DOCUMENTS

3

3.0

MATERIALS

4

4.0

COATING REQUIREMENTS

6

5.0

APPLICATION METHOD

6

6.0

EQUIPMENT

7

7.0

COATING OF FIELD WELDS

7

8.0

CURING

8

9.0

MEASUREMENTS & LOGGING

9

10.0

IDENTIFICATION

10

11.0

INSPECTION AND TESTING

10

12.0

TESTING METHODS

11

13.0

PERMISSIBLE REPAIRS TO THE COATING

12

14.0

HANDLING

13

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SPECIFICATION FOR PIPELINE CONCRETE COATING

1.0

SCOPE

1.1

This specification covers the minimum requirements for the materials, application, inspection, handling and other activities for external concrete coating for pipelines.

1.2

This specification shall be read in conjunction with the conditions of all specifications and documents included in the contract between company and contractor.

1.3

CONTRACTOR shall execute the work in compliance with all laws, by-laws, ordinances, regulations, etc. and provide all services and labour, inclusive of supervision thereof, all materials, equipment, appliances or other things of whatsoever nature required for the execution of the work, whether of a temporary or permanent nature.

1.4

This document is not intended to be all-inclusive, and the use of the guidelines set forth does not relieve the contractor of his responsibility to supply a product capable of performing its intended service.

2.0

RFEFERENCE DOCUMENTS a)

IS 8112

Indian standard specification for 43 grade ordinary Portland cement.

b)

IS 383

Indian standard specification for coarse and fine aggregates from natural sources for concrete.

c)

IS 2386

Indian standards methods of test for aggregates for concrete

Part 1 To VIII d)

IS 4826

Specification for hot dipped galvanized coatings on round steel wires

e)

IS 1566

Specifications for hard drawn steel wire fabric for concrete reinforcement

f)

IS 432

Specification for mild steel and medium tensile steel bars and hard drawn steel wire for concrete reinforcement.

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Method of sampling and analysis of concrete.

h) ASTM C309

Liquid membrane forming components for curing concrete

i) IS 456

Code of practice for plain & reinforced concrete

j) IS 516

Methods of tests for strength of concrete

k) IS 4031

Methods of Physical tests for hydraulic cement

l) IS 4032

Methods of chemical analysis of hydraulic cement

m) IS 1916

3.0

OF

Steel Cylinder Pipes with Lining and Coating- Specification

MATERIALS

The contractor shall supply all the materials necessary for the performance of the work. Materials for concrete coating shall comply with the following requirements.

3.1

Cement

43-grade ordinary Portland Cement conforming to IS 8112 shall be used. Cement which has hardened or partially set or which has become lumpy shall not be used. Test certificates from the cement manufacturer shall be supplied to the company for all cement delivered to site.

3.2

Aggregates

3.2.1

Aggregate shall comply with the requirements of IS-383 and shall be tested in accordance with IS-2386.

3.2.2

Fine aggregates:

Fine aggregate shall mean any of the following as defined in IS 383.

i)

Natural sand

ii)

Crushed stone sand

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Crushed gravel sand

iii)

Sand shall be well graded from fine to coarse in accordance with Table 4 of IS 383.

3.2.3

Aggregates shall be clean and free from injurious amounts of salt, alkali, deleterious substances or organic impurities that may affect the strength of concrete.

3.3

Water

The water shall be fresh and clean and shall be free from injurious amount of oils, acids, alkalies, salts, sugar, organic materials or other substances that may be deleterious to concrete or steel. It shall not contain chlorides, sulphates and magnesium salts. Water from doubtful sources shall be tested by the CONTRACTOR at his expense and approved by the Engineer-in-charge before use.

3.4

Reinforcement

3.4.1

Reinforcement shall consist of 50 mm x 50 mm x 3 mm diameter galvanized welded wire fabric in rolls or in sheet to satisfy the application requirement.

3.4.2

Reinforcing mesh shall conform to IS 432 for steel wire, IS 1566 for welded wire mesh and IS 4826 for galvanized steel. Minimum steel in both longitudinal and transverse direction shall be 0.5% of the concrete cross sectional area, or 3 mm dia wire @ 50 mm c/c whichever is more. For coating thickness of 50mm and above, two layers of mesh shall be provided clear cover being 5 mm from either side.

3.4.3

Alternative reinforcement, having steel cross sectional area per metre of concrete coat, equal to or more than area of the mesh mentioned above, may be submitted for approval.

Reinforcing steel shall be spooled on with a lap of not less than 25 mm (1 inch) or one mesh whichever is greater. thickness.

It shall be embedded approximately midway in the concrete coating

The reinforcing wire shall not contact the pipe corrosion coating. If the concrete

thickness is equal to or greater than 50 mm, at least two layers of mesh shall be installed.

3.4.4

The reinforcing materials shall not be in physical or electrical contact with the pipes. Reinforcement shall rest on synthetic resin spacers forming a crown, whose number shall be such

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as to avoid any contact with the pipes’ protective coating.

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Spacing between the two crown

centers shall be 500 to 1000 mm.

All materials supplied by the contractor, which in the opinion of company, do not comply with the appropriate specifications shall be rejected and immediately removed from site by contractor at his expenses.

4.0

COATING REQUIREMENTS

4.1

Pipes shall be concrete coated to a thickness as specified in the drawings and documents. The concrete unit weight shall be minimum 2300 kg/m3 and the compressive strength shall not be less than 250 kg/cm2 in 28 days.

4.2

Contractor shall design the mix by suitably proportioning the materials to achieve the specified requirements of concrete strength, density and weight with a minimum cement content of 600kg/m3.

5.0

APPLICATION METHOD

5.1

Concrete coating shall be applied either using casting or impingement method. Any alteration or modifications to the methods described in this specification shall be submitted to the Owner/ Engineer-in-charge for approval.

The application method shall however ensure the basic

characteristics of concrete coating in compliance with the minimum requirements of this specification.

5.2

Contractor shall submit to the “Engineer-in-charge”, prior commencement of work, the procedure/method of application for approval. Wherever practical the total thickness shall be applied in a single pass. If more than one application is required to produce a coating of the specified thickness, then the time allowed between successive applications shall not exceed 30 minutes. If the time between coats exceeds 30 minutes, all previous coating shall be removed and shall be recoated.

The cost of removing coating and recoating shall be at contractor’s

expense.

5.3

All pipes shall be kept clean and free from cement, concrete & grout either inside or outside of the uncoated section.

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Cutback on concrete coating.

Both ends of each joint for a distance of 305 mm ±25 mm shall be completely free of concrete to facilitate field joints. The concrete shall be tapered backside at these points at a minimum two to one slope, until the required thickness of coating is reached. Also it shall terminate approx. 50 mm short of the end of the corrosion coating applied to the pipe surface.

6.0

EQUIPMENT

6.1

The equipment used for performing the concrete coating shall be capable of doing so with a reasonable degree of uniformity with respect to thickness, density and strength.

The

proportioning equipment and procedure shall be of the type to assure consistently proportioned materials by weight. Concrete shall be mixed in mechanical mixers, which shall ensure thorough mixing of all materials. Any equipment that tends to separate the ingredients shall not be used. In all cases concrete shall be placed within 30 minutes after water is first added to the mix. Before placing fresh concrete against the joint, the contact surfaces shall be carefully cleaned and wetted to obtain a good bond between the fresh material and previously placed materials.

7.0

COATING OF FIELD WELDS

7.1

The contractor shall coat the uncoated pipe surface at field welds in accordance with methods approved by the company.

Contractor shall submit a detailed procedure for joint coating for

company’s approval.

The reinforcement for the field welds shall be the same as that for line pipe coating with the same

7.2

number of layers and the same space between layers as for the existing coating. The edges of this netting must be carefully secured with galvanized wire to the reinforcement extending from the existing coating.

7.3

The reinforcement shall not make direct or electrical contact with the pipe.

7.4

Synthetic resin spacer blocks may be used to keep the reinforcement free from the pipe coating.

7.5

The moulds used for applying the concrete coating shall be supplied by the contractor.

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7.6

The composition of the concrete shall be same as that of the concrete coating of the pipe.

7.7

When using moulds, the contractor shall prevent air being trapped by applying mechanical vibrators or by striking the outside of the mould by sticks.

7.8

If the moulds remain around the pipe, eg: in the case of submerged pipes floated into position, the contractor shall take appropriate measures to prevent too much water entering the mould. This can be achieved by clamping strips of burlap between the ends of the mould and the existing concrete coating. After the mould has been filled with concrete the opening for filling must also be closed off.

8.0

CURING

8.1

Immediately after concreting, the exposed surfaces of the concrete shall be protected during hardening from the effects of sunshine, drying winds, rain etc and then after the initial set has taken place, the concrete coating shall be properly cured. The coated pipe shall be handled gently by suitable means to prevent undue distortion.

8.2

During curing the concrete coated pipe shall be racked on sand ridges or on flat earth surface free of obstruction.

If the joints are placed on sand ridges they should be so placed as to

eliminate any injurious deflection in the pipe. The concrete shall be cured by application of curing membrane approved by the Engineer-in- charge.

8.3

Curing shall be performed by application of an approved curing membrane using sealing compounds and shall meet the requirements as mentioned in the manufacturer’s specifications. The material shall be stored, prepared and applied in strict conformity with the instructions of the manufacturer. The ingredients of any such compound shall be non-toxic and non-inflammable and shall not react with any ingredient of concrete, the reinforcement, the protective coating or pipe. The application of this curing compound shall take place immediately after the coating is completed and preferably before the pipe is removed from the concrete coating apparatus.

8.4

The surface of the concrete shall be lightly sprayed with water before applying the curing compound or as specified in the manufacturers specifications. The pipe surface shall be kept wet during day light hours for (7) seven days after application of the concrete coating. The concrete shall not be allowed to dehydrate.

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All concrete coated pipes shall be cured continuously for a period of seven days. Pipe shall not be handled or loaded out from the yard until so cured. No deviation from this requirement shall be permitted.

Transportation/handling of concrete coated pipe shall be done after 28 days of

concreting.

9.0

MEASUREMENTS & LOGGING

9.1

All measurements as mentioned below shall be taken during the work stages and clearly logged in a proper log-book. A separate log-book shall be used for recording tests and trial results.

9.2

Pipes having same nominal diameter, steel wall thickness and protection coating shall be recorded in a single register.

9.3

The following shall be entered in the log book for each pipe length.

a)

Line pipe

i.

Field identification number (F)

ii.

Mill serial number (M)

iii.

Length (L)

iv.

Weight (BW)

v.

Average outside diameter (OD)

(Shall be obtained by measuring the girth at least at five places, two of which 400 mm from the ends of pipe and the other equispaced between them)

b)

Concrete coating

i.

Batch identification number (B)

ii.

Date of concrete coating (TD)

iii.

Average concrete coating thickness (CT)

iv.

Dry weight of concrete coated pipe and date of weighing, after 28 days

(DW) of

application of concrete.

9.4

No concrete coating shall be allowed unless all the details pertaining to the pipe before coating are entered in the log-book. In addition each batch/shift shall be identified and registered against

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cube samples/core samples taken for crushing strength tests, and the same shall be logged.

10.0

IDENTIFICATION

10.1

A certified permanent records shall be supplied to Engineer-in-charge showing the serial number, average outside diameter, length and weights.

Pipe identification shall be maintained by the

contractor for each joint of pipe and restencilling pipe mill coding shall be done on the internal surface of the pipe.

10.2

For each concrete coated pipe length, at one of the two ends, the field identification number and the date of concrete placing shall be marked.

11.0

INSPECTION AND TESTING

11.1

Contractor shall provide the method and means of obtaining the weight, length, and average outside dia of each joint of pipe immediately after being coated. A permanent record certifying such data shall be compiled daily and copies of such records shall be promptly be made available to Engineer-in-charge.

11.2

Contractor shall furnish all materials to be tested and required testing apparatus. Contractor shall obtain test samples in accordance with the applicable standard specification for the concrete being applied and shall provide company with the results of tests made on these samples. Samples shall be taken and tests performed at least once per shift during continuous operation or once for every twenty five joints for non continuous operations.

11.3

The Engineer-in-charge or his representative shall have full and free access to the office and/or plant, every part of the coating yard, and the ON/OFF loading facilities of the contractor. Contractor shall assist the Engineer-in-charge or his representative for inspecting the works at every stage. Pipe coating not meeting requirements, as outlined herein, shall be rejected.

11.4

Causes for rejection of the concrete coating shall include, but not be limited to, the following:

a)

Coatings that weighs less than or more than five (5) percent of the weight specified.

b)

Improper placement of reinforcing steel

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Coating damaged in handling or storage that is considered by Engineer-in-charge to be excessive and beyond repair.

d)

Coating that are allowed to remain unfinished for a period of time exceeding 30 minutes, as in the case of breakdown, or otherwise.

e)

Any failure to meet the requirements of this specification.

In general substandard concrete coating causing lesser weight, improper placement of steel, coating damage and unfinished concrete etc. shall lead to rejection of the concrete coating and decision of the Engineer-in-charge in this respect shall be final.

12.0

TESTING METHODS

12.1

Samples of the concrete mix, as applied during the coating operation, shall be taken to determine the compressive strength and density of the concrete coating.

12.2

All testing shall be at the contractor’s expense and as directed by the Engineer-in-charge or his representative. The testing methods to be used are outlined below.

a)

Compressive strength test

i.

Concrete shall be so proportioned so as to produce a compressive strength of not less than 250 kg/cm2 at 28 days and not less than 167 kg/cm2 in 7 days. Test shall be carried out as per the relevant Indian standards.

ii.

Minimum of six (6) cubes, three (3) each for 7 days strength and 28 days strength shall be taken. Copies of all test reports shall be made for 7 days and 28 days strength as decided by the Engineer-in-charge and the contractor.

b)

Coated pipe tolerance and weight tests

i.

Contractor shall maintain a surface tolerance of +/- 6 mm maximum for 30 mm thick and +8mm/-6mm for thickness above 30 mm over outside diameter of the coated pipe, between high and low elevations of pipe.

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ii.

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The acceptable weight tolerance for any pipe shall be limited to +5/-2 % of the calculated theoretical weight. The theoretical weight shall be calculated using total weight of the pipe with concrete and corrosion coating.

13.0

PERMISSIBLE REPAIRS TO THE COATING

13.1

The following are repairs that will be permitted to coating due to unavoidable damage in handling and storage. This is applied only to concrete that has hardened.

13.2

Spalling is defined as damage, which cause a loss in concrete of more than 25% of the total thickness of the coating at the point of damage. Damage due to spalling of an area of less than 0.1m2 (1 ft2) where remaining concrete is sound will be accepted without repairs. Damage due to spalling of an area more than 0.1 m2 and less than 0.3 m2 shall have the concrete removed as necessary to expose the reinforcing steel throughout the damaged area. Edges of the spalled area shall be undercut so as to provide a key lock for the repair material. A stiff mixture of cement and aggregate of 1:3 ratio shall be trowelled into and through the reinforcement and built up until the surface is level with the coating around the repair. The pipe shall then be carefully laid with the repaired area at the top and shall be moist cured for a minimum of thirty six ((36) hours before further handling. If the damaged area is more than 0.3 m2, the coating shall be removed around the entire damaged area.

The repairs shall be made by satisfactorily restoring the

reinforcement, forming the area with a metal form and pouring a complete replacement of materials similar to that from which the coating was made. The mixture shall be one (1) part of cement, three (3) parts of aggregate and necessary water to produce a slump not to exceed 100 mm. The resulting coating shall be equal in weight, density, uniformity, thickness, strength and other characteristics to the originally applied coating. The pipe shall then be carefully laid in a position where it shall be allowed to remain for a minimum of thirty six (36) hours before further handling.

14.0

HANDLING

14.1

Pipes shall be handled in a manner to prevent damage to coating, pipe walls and beveled ends. Adequate strapping and padding shall be provided when loading for transfer to any location.

14.2

Pipes shall be raised or lowered to or from the stockpile, ground barge, truck by using brass lined end hooks inserted in the ends of the pipe, and carried by a canvas sling with a spreader bar

FACT 12FT026A/94

EGIEERIG AD DESIG

ORGAISATIO

DATA SHEET

SPECIFIC REQUIREMETS

OF

WORK

8122- 12 - DA - 002 PAGE 13 OF 13

R0

between the lines. All pipe handling shall be with equipment approved by Engineer-in-charge or his representative. Contractor shall submit written handling, stacking and storage procedure for approval of the Engineer-in-charge.

14.3 If the Engineer-in-charge or his representative observed coating or pipe damage due to handling, the contractor shall take immediate corrective action. Finally, pipe shall not be loaded or stacked until such handling will not damage the concrete coating.

FACT 12FT026A/94

EGIEERIG AD DESIG

ORGAISATIO

DATA SHEET

SPECIFIC REQUIREMENTS OF WORK

8122- 12– DA - 001 PAGE 1 OF 14

MANGALORE LPG BLENDING FACILITIES

SPECIFICATION FOR CEMENT MORTAR LINING INSIDE PIPELINES

PREPARED FOR

HPCL PROJECT NO. 8122

OCTOBER 2009

0

19.10.2009

LTA

SA

SA

REV.

DATE

PRPD. BY

CHKD. BY

APPRD. BY

FACT 12FT026/94

ENGINEERING AND DESIGN

ORGANISATION

DATA SHEET

SPECIFIC REQUIREMENTS OF WORK

8122- 12 - DA - 001 PAGE 2 OF 14

TABLE OF CONTENTS

1.0

Scope Of Work

3

2.0

Reference Documents

3

3.0

Materials

4

4.0

Application

5

5.0

Curing

7

6.0

Procedure Qualification

7

7.0.

Inspection

8

8.0

Repair Of Lining

9

9.0

Pipe Jointing

9

10.0

Fittings And Flanges

10

11.0

Branch Connection

10

12.0

Cutting Methods For Cement Lined Pipes

10

13.0

Damage Protection

11

14.0

Installation

FACT

ENGINEERING AND DESIGN

12FT026A/94

11

ORGANISATION

DATA SHEET

SPECIFIC REQUIREMENTS OF WORK

8122- 12 - DA - 001 PAGE 3 OF 14

SPECIFICATION FOR PIPELINE CEMENT MORTAR LINING

1.0

SCOPE

1.1

This specification covers the minimum requirements for the materials, mixing, application of cement lining, curing, inspection, repair, handling, transportation and other activities for internal cement mortar lining for pipelines.

1.2

This specification shall be read in conjunction with the conditions of all specifications and documents included in the contract between company and contractor.

1.3

CONTRACTOR shall execute the work in compliance with all laws, by-laws, ordinances, regulations, etc. and provide all services and labour, inclusive of supervision thereof, all materials, equipment, appliances or other things of whatsoever nature required for the execution of the work, whether of a temporary or permanent nature.

1.4

This document is not intended to be all-inclusive, and the use of the guidelines set forth does not relieve the contractor of his responsibility to supply a product capable of performing its intended service.

2.0

RFEFERENCE DOCUMENTS

a) ANSI/ AWWA C 205 – 00

Cement mortar Protective Lining and Coating for Steel water pipe- shop Applied

FACT 12FT026A/94

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ORGANISATION

DATA SHEET

SPECIFIC REQUIREMENTS OF WORK

8122- 12 - DA - 001 PAGE 4 OF 14

pipe- shop Applied b)

IS 8112

Indian standard specification for 43 grade ordinary Portland cement.

c)

IS 383

Indian standard specification for coarse and fine aggregates from natural sources for concrete.

d)

IS 2386

Indian standards methods of test

Part1 To VIII for aggregates for concrete e)

IS 1199

Method of sampling and analysis of concrete

f)

IS 456

Code of practice for plain & reinforced concrete

g)

IS 4031

Part 6 – Determination of compressive strength of hydraulic cement.

h)

IS 1916

Steel Cylinder Pipes with Concrete Lining and Coating Specification

i)

3.0

IS 4032

Methods of chemical analysis of hydraulic cement

MATERIALS

The contractor shall supply all the materials necessary for the performance of the work. Materials for cement mortar lining shall comply with the following requirements.

FACT 12FT026A/94

ENGINEERING AND DESIGN

ORGANISATION

DATA SHEET

3.1

SPECIFIC REQUIREMENTS OF WORK

8122- 12 - DA - 001 PAGE 5 OF 14

Cement

43 grade ordinary Portland Cement conforming to IS 8112 shall be used. Cement which has hardened or partially set or which has become lumpy shall not be used. Test certificates from the cement manufacturer shall be supplied to the company for all cement delivered to site.

3.2

Fine aggregates:

Fine aggregate shall mean any of the following as defined in IS 383. i)

Natural sand

ii)

Crushed stone sand

iii)

Crushed gravel sand

Sand shall consist of inert granular material and the grains shall be strong, durable and uncoated. Sand shall be clean and free from injurious amounts of dust, clay, flaky particles, oil, alkali, mica and other deleterious substances. Sand shall conform to IS:383 Grading Zone III.

3.3

Water

The water used for cement mortar mixing and curing shall be fresh and clean and shall be free from injurious amount of oils, acids, alkalies, salts, sugar, organic materials or other substances that may be deleterious to concrete or steel. It shall not contain chlorides, sulphates and magnesium salts. Water from doubtful sources shall be tested by the Contractor at his expense and shall be approved by the Engineer-in-charge before use.

FACT 12FT026A/94

ENGINEERING AND DESIGN

ORGANISATION

DATA SHEET

SPECIFIC REQUIREMENTS OF WORK

8122- 12 - DA - 001 PAGE 6 OF 14

4.0

APPLICATION

4.1

Cement Mortar mixing

Cement lining shall be done in the field shop, which may be outside the project site boundary. Suitable mechanical equipment capable of mixing mortar and doing the lining work to a reasonable degree of uniformity with respect to thickness, density and strength shall be employed. Mortar shall be mixed in batches.

Mortar shall compose of cement, sand and water and mixed well in proper consistency to obtain a dense, homogeneous lining that shall adhere firmly to the pipe surface. Cement mortar for lining shall consist of one part cement to not more than three parts sand by weight and shall have a minimum cement content of 600kg/m3. Water to cement ratio shall be between 0.3 to 0.4 by volume.

Trial mixes shall be made to arrive at mix to achieve the requirements specified in procedure qualification clause 6.0 below:

4.2

Surface Preparation & Primer Application

Pipes shall be welded in suitable length and immediately prior to lining, the surface shall to be thoroughly cleaned removing all grease, scale, dust, etc. by power tool to St. 3 as per IS 9954. Surface cleaning shall be followed by spray application of welding grade of inorganic Zinc silicate prefabrication primer from approved paint manufacturers with a dry film thickness of 25 microns at both the pipe ends upto 100 mm pipe length. The cement lining shall be done at least after 10 hours of drying of the prefabrication primer to avoid damage of the primer. Suitable products are such as Inter plate – 11 from M/s AKZO NOBEL FACT 12FT026A/94

ENGINEERING AND DESIGN

ORGANISATION

DATA SHEET

SPECIFIC REQUIREMENTS OF WORK

8122- 12 - DA - 001 PAGE 7 OF 14

Coatings (India) Ltd., Bangalore, Carboweld – 11 from M/s Carboline products Chennai.

4.3

Application Method

The lining shall be applied in one course for the pipe section. No unfinished surface shall remain exposed for more than 20 minutes. Mortar shall be handled so as to avoid any kind of segregation and excessive moisture loss. During mortar application pipe should be at ambient temperature. If pipe is hot due to such reasons as lying in the hot sun, then the pipe must be cooled with the help of wet gunny bags prior to application of mortar. Lining shall be free of any sharp corners and edges and must be suitably contoured/rounded prior to curing.

Straight sections of pipe shall be lined by using spinning method or a method known to provide equivalent results such as by a machine traveling through the pipe and distributing the freshly mixed mortar uniformly along the full section and long radius bends of the pipe. The lining machine shall be provided with attachments for mechanically trowelling the mortar.

Both the application and

trowelling of the mortar shall take place at the rear of the machine so that the freshly placed and trowelled mortar will not be damaged. The trowel attachment, the rate of travel of machine and the rate of discharge of mortar shall be such that the pressure applied to the lining will be uniform and produce a lining of uniform thickness with a smooth, finished surface.

Hand patching at the end of the pipe, for length not more than 100 mm length, shall be permitted to rectify the thinning of linings.

Fittings and specials shall be centrifugally spray lined to the same standard as straight pipes or, if this is precluded by their shape, be hand patched so as to FACT 12FT026A/94

ENGINEERING AND DESIGN

ORGANISATION

DATA SHEET

SPECIFIC REQUIREMENTS OF WORK

8122- 12 - DA - 001 PAGE 8 OF 14

achieve comparable results.

The thickness of lining shall be as per Drg No. 8122-12-DG-00001, however to accommodate the disc movement of Butterfly valves the cement lining of the mating flanged spools shall be suitably tapered keeping minimum 3 mm lining thickness.

5.0

CURING

After lining, the pipes shall be marked with the date of lining and shall be covered with plastic caps and shall be moved carefully to a curing yard. The curing area shall be sheltered so that lined pipes and fittings are protected from harmful climatic conditions.

Moist curing shall start after 24 hours of completion of cement lining and shall be done by continuous wetting or ponding. Under no circumstances the lining shall be allowed to dry during curing period. Curing shall be carried out for a minimum period of 7 days.

6.0

PROCEDURE QUALIFICATION

Prior to the application of the shop cement lining the manufacturer shall perform procedure tests and qualify a working procedure to demonstrate that he is able to produce a lining system in accordance with design requirement.

The

constituents, mortar & finished pipes shall be tested. To establish the correct combination of sand & water, minimum of five samples shall be prepared. For each mix following shall be accurately checked and recorded.

For individual constituents FACT 12FT026A/94

ENGINEERING AND DESIGN

ORGANISATION

DATA SHEET

SPECIFIC REQUIREMENTS OF WORK

8122- 12 - DA - 001 PAGE 9 OF 14

-

Cement

-

Sand

-

Water

-

Proportions & weights of respective materials

For Cement Mortar Test Specimen

-

Density

-

Compressive Strength

-

Water absorption

Test blocks of this material when subjected to testing as per IS 4031 shall exhibit compressive strength of not less than 250 Kg/Sq.cm. after 28 days of curing and the density of cured lining shall not be less than 2300 kg/cu.m. Water absorption as per ASTM C642 shall not exceed 10% for the test specimen. Based on the test results a procedure shall be standardised for mixing of the materials.

Inspection personnel shall witness the mixing of materials and sample preparations for procedure qualification.

Test results shall be correlated with

sample no. and a standard procedure shall be evolved.

7.0

INSPECTION DURING PRODUCTION

The entire procedure of applying cement-mortar lining shall be subjected to continuous inspection by Owner or their authorised representative.

However,

such inspection shall not relieve the contractor of the responsibility of meeting the specifications. The job shall be subjected to inspection at the following stages:

i) FACT 12FT026A/94

After surface preparation and prior to application of lining

ENGINEERING AND DESIGN

ORGANISATION

DATA SHEET

SPECIFIC REQUIREMENTS OF WORK

8122- 12 - DA - 001 PAGE 10 OF 14

ii)

After application and curing

Any lining not applied in accordance with this standard or not as per required thickness shall be subjected to rejection and replaced/repaired at the expense of the contractor.

The inspector shall have free access to all areas and facilities concerned, and the contractor shall furnish all reasonable assistance.

The inspection of lining in pipe upto 600NB shall be made from both ends of the lined pipe segment by using strong lights and/or mirrors. The inspection shall be done before the lining has attained its initial set. For pipes 650NB & above, a manual, visual inspection of the lined pipe interior shall be made.

Defects in cement mortar lining include, but are not limited to sand pockets, voids, over sanded areas, honey comb, excessively cracked, drummy areas, areas of lining thinner than specified and areas of unsatisfactory surface finish.

The surface of lining shall be smooth and free from irregularities, cracks upto 0.8 mm wide and not over 300 mm in length are acceptable. Trough to crest height shall not exceed 1.0 mm.

8.0

REPAIR OF LINING

8.1

For pipes up to 600NB, the defective lining shall be removed in total from the pipe segment before the initial setting. The pipe segment shall then be relined in full compliance with specifications.

8.2

For pipes above 600NB, small defective areas shall be repaired by manual

FACT 12FT026A/94

ENGINEERING AND DESIGN

ORGANISATION

DATA SHEET

SPECIFIC REQUIREMENTS OF WORK

8122- 12 - DA - 001 PAGE 11 OF 14

removal of the defective lining and by hand reapplication of mortar lining. Defective areas encompassing the full diameter of the pipe shall be replaced by machine wherever practical.

8.3

A pipe that has been exposed by spilling or cracking of the lining shall be cleaned thoroughly free from debris.

8.4

When an epoxy pipe-joining compound is to be used for the repair, the surface shall be dry and dust free and a coating of the compound shall be applied with a small trowel or spatula. When the cement mortar mix is to be used, the surface shall be dust free and moistened with clean fresh water.

Immediately after

moistening the cement mortar mix shall be applied using a small trowel.

If

necessary a brush can be used for “feathering in” the surface edges of the repair.

8.5

Where cement mortar is used for the repair, the adjacent lining shall be coated far enough back to cover any visible cracks and shall be maintained in a moist condition for three days using a wet hessian sack or similar means. Alternatively, if the line can be filled, it shall be put into use after the initial set has taken place.

9.0

PIPE JOINTING

Pipe joints both for above ground and underground upto 600NB shall be done by collars in general and by flanged fittings in specific cases wherever requirement arises for ease of fabrication, inspection and maintenance. Typical joint details shall be as shown in Drg. No.8122-12-DG-00001.

9.1

Jointing Methods

9.1.1 Pipes which have been cement-mortar lined cannot be butt welded together in the normal way as the mortar adjacent to the weld will be damaged by heat.

FACT 12FT026A/94

ENGINEERING AND DESIGN

ORGANISATION

DATA SHEET

SPECIFIC REQUIREMENTS OF WORK

8122- 12 - DA - 001 PAGE 12 OF 14

9.1.2 For pipe size upto 600NB, Pipe OD and sleeve ID & both end faces of the cement lining shall be provided with epoxy coating. The sleeve welds should be located at 90 deg. clear of any longitudinal pipe weld.

9.1.3 The terminal ends shall be cut at right angles to the pipe axis and after completion of all welding out of roundness shall be within the limits specified by API Spec. 5L.

10.0

FITTINGS & FLANGES

All fittings upto 600NB size shall be generally collar joined with pipe. However flanged joints can be provided at critical locations for ease of fabrication, inspection and maintenance. Flanges may be welded in field/shop prior to lining. Flange faces shall be free of cement lining. For detail refer Drg. No.8122-12-DG00001.

11.0

BRANCH CONNECTION

11.1 Branches in cement lined pipes shall be of minimum of 150 NB size. Stub in branch connections of size 150 NB onward shall be collar joined as per Drg. No.8122-12-DG-00003.

However to meet specific requirement at critical

locations for ease of fabrication, inspection and maintenance flanged joints may also be used as per Drg. No.8122-12-DG-00003.

11.2

Instruments branches for Pressure instruments shall be as per Drg. No.812212-DG-00002.

The

150NB

blind

flange

shall

be

drilled

to

suit

instrument/vent/drain size.

11.3

Vents and drains on cement-lined piping shall be by 150NB flanged stub with

FACT 12FT026A/94

ENGINEERING AND DESIGN

ORGANISATION

DATA SHEET

SPECIFIC REQUIREMENTS OF WORK

8122- 12 - DA - 001 PAGE 13 OF 14

blind flange, which is internally epoxy (FRE) lined. The blind flange shall be provided ¾” tapped hole and ¾” vent/drain with valve & blind.

12.0

CUTTING METHODS OF CEMENT LINED PIPES

12.1

For cutting lined pipe, a slitter saw supported as necessary and containing a nylon bonded carborundum disc shall be used. Alternatively, a rigid pipe cutting machine using tungsten carbine tipped tools ground to the cutting angles shall be used.

12.2 On fusion welded steel pipes, the external weld shall be removed flush with, but not below, the face of the pipe for the width of the cutters, and if necessary for the complete width of the cutting machine.

12.3 The section to be removed and the adjacent pipe ends shall be suitably supported to avoid imposing any weight on the concrete lining when breaking through.

13.0

DAMAGE PROTECTION

13.1 Handling

Handling of lined pipe lengths shall be by means of nylon belts such that the pipes are supported 1/5 of their length from each end. Pipe shall not be lifted using hooks inserted in the pipe ends.

13.2

Transportation

13.2.1 Lined pipes being transported shall be adequately supported in a level horizontal position in order to minimize flexing and prevent induced bending and damage to the lining. FACT 12FT026A/94

ENGINEERING AND DESIGN

ORGANISATION

DATA SHEET

SPECIFIC REQUIREMENTS OF WORK

8122- 12 - DA - 001 PAGE 14 OF 14

13.2.2 Pipes shall be protected from direct and indirect impact by means of suitable cushioning material.

13.2.3 Pipes shall not be transported using tractor units with trailing bogies or other method offering no central support.

13.2.4 During transportation and storage pipe lengths shall have end caps or other suitable means of protection, with sufficient holes to permit air circulation, provided this does not cause drying out and cracking of the lining. Means shall be taken to ensure that the end protection remains securely fastened, especially during transportation.

13.2.5

Branch connections shall be suitably plugged or capped as described above.

14.0

INSTALLATION

14.1

Care shall be taken when handling jointed lengths of pipes to ensure that the induced bending and the possibility of damage to the lining is minimized.

14.2

During pipeline installation, when handling, lifting and laying pipe, the spacing of lifting points and supports shall be adequate to avoid induced bending.

FACT 12FT026A/94

ENGINEERING AND DESIGN

ORGANISATION

DATA SHEET

FIRE HYDRANT SYSTEM

8122-01-DA- FH101 PAGE

Applicable to : Site : Unit : 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0

15.0

16.0 17.0 18.0 19.0 20.0

Purchase X Proposal MANGALORE LPG BLENDING FACILITY

Make Model Type No. off Codes / Standards Monitor size Connection size Nozzle diameter Base flange details Type of joint Design pressure Back pressure at base flange Water barrel pipe thickness Perfomance Flow rate Pressure Jet length - Horizontal - Vertical Rotation Angle - Horizontal plane - Vertical plane Material of construction Base flange Swivel joints Water barrel Nozzle Locks for swivel joints Lubrication Accessories Monitor weight Certification Test pressure

As built

1

OF

TPS No. :

Job No : Item No. : WATER MONITOR

1 8122

Stand post type with swivel joints, Type 1 of IS 8442 2 IS 8442 75 with 100 NB base flange

mm mm mm

Kg/cm2G Kg/cm2G mm lpm Kg/cm2G M

32 100 NB, ANSI B16.5, Class 150, SORF Swivel joints 7 operating / 15 design IS 1239, Heavy

1750 7 53 20

Deg. 360 +80, (-)45 CS Gun mettal IS 1239 Seamless Aluminium alloy Gun mettal Grease lubrication for joints Kg Kg/cm2G

ISI marking 23

FACT ENGINEERING AND DESIGN ORGANISATION

1

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55

02ES023/97

ENGINEERING SPECIFICATION

PAINTING PAGE

1 OF

CONTENTS: 1.0.0. SCOPE 2.0.0. MATERIALS 3.0.0. SURFACE PREPARATION 4.0.0. STORAGE OF PAINTING MATERIALS 5.0.0. MIXING AND THINNING 6.0.0. PAINTING 7.0.0. SAFETY 8.0.0. INSPECTION 9.0.0. GUARANTEE 10.0.0. CODIFICATION OF PAINTING MATERIALS 11.0.0. SCHEME OF PAINTING 12.0.0. COLOUR CODING & MATERIAL FOR PIPING TABLES

PRPD.BY:- RS

CHKD.BY:- GPN

APPRD. BY:- KV

FACT ENGINEERING AND DESIGN ORGANISATION

ISSUED ON:- 23.07.97

13

02ES023/97

ENGINEERING SPECIFICATION

PAINTING

1.0.0. SCOPE

a)

1.1.0. This specification covers the requirements for surface preparation, painting and painting materials for equipment, structures and piping (including those painted/primed at shop and those painted at Field/Site.

b) c) d) e) f) g) h) i)

1.2.0. Requirement of painting for any item shall be as specified in any of the following documents. a) b) c) d)

Equipment Data Sheet Piping line schedule Design Basis for items Painting schedule

package

1.3.0. The purpose of painting described in this specification is generally for protection against corrosion. 1.4.0. Painting for other reasons shall be as indicated in the respective equipment data sheets or painting schedule. 1.5.0. The following surfaces exposed to atmosphere are covered by this specification, which are not provided by any other form of covering/coating. a)

b) c) d)

PAGE 2 OF

Pressure vessels, Tanks, Heat Exchangers and other process equipment with Carbon steel and low alloy steel as material of construction. Machinery items including motors. Steel structures Carbon and low alloy steel piping

1.6.0. The following items shall not be painted unless otherwise specifically required by respective equipment Data Sheets/Painting schedule

j)

13

Non ferrous surfaces, stainless steel and High Alloy steel surfaces. Glass, tile or ceramic surfaces Name plates and identification tags Valve stems Machined contact surfaces Galvanised surfaces Insulation covers Plastics Underground / buried piping and equipments which are provided with special type of protective coatings. Surfaces / Items which are excluded from painting due to specific reasons.

1.7.0. This specification also covers painting of “Markings” and color-coding of carbon steel, low/high alloy steel, stainless steel, galvanized iron and insulated pipes. 2.0.0. MATERIALS 2.1.0. All painting materials shall be of good quality as covered by respective IS or other international specifications 2.2.0. Special paints and painting materials shall have proven quality and shall meet the requirements laid down in the respective data sheets for equipment and piping. 2.3.0. All painting materials shall not have passed the date of expiry or shelf life as recommended by manufacturer. 3.0.0

SURFACE PREPARATION

3.1.0

All surfaces to be painted shall be free from rust, oil, grease, dust, stain, moisture or any other foreign material/contamination, as per IS 1477 Part I.

FACT ENGINEERING AND DESIGN ORGANISATION

02ES023/97

PAINTING

ENGINEERING SPECIFICATION Surfaces to be completely dry.

be

deg.C or when the relative humidity of air exceeds 90%.

3.3.0

Oil, grease, stains and other similar contaminants shall be completely removed by using proper solvents and removers, After cleaning, the surfaces shall be free from even traces of contaminants and solvents/removers.

3.9.3. Blasting operations shall not be carried out during rain, snow, or strong winds.

3.5.0

shall

13

3.2.0

3.4.0

painted

PAGE 3 OF

Dust shall be removed by air blowing or vacuum cleaning. Hard and caked dust, mud, mill scale and rust shall be removed by mechanical means like wire brushing, sand blasting , shot blasting or grit blasting.

3.6.0

Wet surfaces shall be dried by blowing warm air.

3.7.0

All surfaces cleaned by different methods shall be painted immediately with out allowing the clean surfaces to gather dust, rust and other external substances.

3.8.0

During the course of painting if it is found that the surfaces are contaminated due to any reason, the same shall be cleaned by any of the methods described earlier, before further proceeding with painting.

3.9.4. Blasting medium viz. Slag, grit, or shot shall be completely dry and shall be free from any sort of contaminants like dust, oil, grease etc. 3.9.5. Blasting air shall be completely dry and shall have minimum pressure of 3.5 kg/cm2 . 3.10.0 Surfaces which are not suitable for blast-cleaning or could not be blastcleaned due to practical reasons shall be thoroughly wire brushed to exhibit a pronounced metallic sheen, equivalent to St 3 as per IS 9954. 3.10.1 Absence of compressed air, slag/shot/grit and/or blasting equipment and accessories shall not be a reason for not carrying out blast cleaning. 4.0.0. STORAGE MATERAILS

OF

PAINTING

4.1.0. Paints, varnishes, thinner, additives and other volatile substances shall be stored in a flame proof enclosure, away from heat.

3.9.0

All surfaces to be painted after sand, grit or shot blasting shall exhibit almost clean white metal and shall have surface finish of SA 2 ½ as per IS 9954.

4.2.0. Fire extinguishers or sand and water for emergency fire fighting operations shall be provided near storage area at easily accessible place for use, in case of fire.

3.9.1

Blast cleaned surfaces shall be primed within 2 hrs, after blasting, before rerusting starts and before contamination.

4.3.0. Warning Boards and signs shall be exhibited around the storage area.

3.9.2. Blast cleaning shall not be carried out when temperatures are less than 20

FACT ENGINEERING AND DESIGN ORGANISATION

02ES023/97

ENGINEERING SPECIFICATION

PAINTING

5.0.0. MIXING AND THINNING 5.1.0

Mixing and thinning of paints shall be carried out as per manufacturer’s recommendations.

5.2.0

Mixing and thinning operations shall be carried out in well ventilated rooms.

5.3.0

Only that quantity of paint which is sufficient to cover the required area within the specified painting time, shall be mixed at a time.

5.4.0

Mixed paints shall be used with in the time span as recommended by manufacturer. Mixed paints, for which standing time specified has elapsed, shall not be used.

5.5.0

5.6.0

Ready-mixed paints containers shall be opened only at the time of painting. Containers shall be closed air tight after drawing paint from it. Ready-mixed paints shall be stirred well before drawing from the storage container as well as during painting operations.

5.7.0

Ready-mixed paints shall be thinned only if absolutely necessary by using thinners commended by manufacturer.

5.8.0

Balance of ready-mixed paints shall not be poured back into the main container after use, but shall be kept in a separate air tight container.

6.0.0

PAINTING

6.1.0

General Requirements.

6.1.1

Painting of equipment, piping and structurals shall be carried out at shop or site as prescribed in the respective eqpt. data sheets, piping line schedule or structural detail drawing.

. 6.1.2

PAGE 4 OF

13

Painting shall not be carried out on surfaces not prepared and not meeting the requirements of clause 3.0.0.

6.1.3

Painting shall be carried out only under favourable conditions. Painting shall not be carried out in dusty and draught conditions in damp areas and during rainy seasons or cold atmosphere.

6.1.4

During painting, adjacent equipments or surfaces shall be protected from paint sprays, splashes or drips.

6.1.5

Painting shall be carried out only by using brushes, rollers, air/airless spray.

6.1.6

Caution boards indicating ‘wet paint’ shall be posted after painting is over and kept till the curing time is completed.

6.1.7

For painting of multiple coating, each coat shall be applied only after sufficient curing time has elapsed after the previous coat, as recommended by manufacturer.

6.1.8

All painted surfaces shall have a uniform and smooth regular finish. The surfaces shall be free from foreign particles, brush marks, bristles, ridges, waves, laps wrinkles etc. If such surface defects occur, the same shall be removed by using abrasive paper/cloth and re-painted.

6.1.9

Surfaces inaccessible after assembly shall be painted to requirement before assembly.

6.1.10 Any imperfect or damaged layer/coat shall be repaired before subsequent coating. 6.1.11 At places where welding is to be carried out at field after assembly, a space of 100 to 200 mm width shall be left unpainted on both sides of the welding joint.

FACT ENGINEERING AND DESIGN ORGANISATION

02ES023/97

ENGINEERING SPECIFICATION

PAINTING

6.1.12 Field welded areas shall be thoroughly cleaned as required in clause 3.0.0 and painted in the same manner as the remaining area. 6.2.0

Shop Painting/Priming.

6.2.1

Shop painting/priming shall be carried out as specified in the respective data sheets/line schedule etc. and shall meet all the requirements of this specification.

6.3.0

Painting at Field /Site.

6.3.1

Field/site painting shall be carried out as specified in the data sheets/painting schedule and shall meet all the requirements of this specification for painting.

6.3.2

Where equipments/piping/structures have already received shop painting/priming, the painted/primed surfaces shall be thoroughly cleaned and inspected for any damage or defects. Such damages or defects shall be repaired before starting the filed/site painting.

7.2.0. Open flames and exposed elements or sources of ignition of any kind shall be prohibited in the area where painting materials are stored and painting operations are carried out. 7.3.0. ‘Warning’ or ‘Caution’ boards indicating chances of fire shall be displaced around the paint storage and painting areas.

13

7.4.0

Electrical fittings and appliances shall be spark proof and shall not cause a fire in the painting storage and painting areas.

7.5.0

Cleaning agents with flash point less than 400 C shall be used.

7.6.0

Adequate ventilation shall be ensured during painting and storage of paints.

7.7.0

Painting workmen shall wear face masks, gloves and protective clothing during painting and mixing operations. In addition, workmen engaged in blasting operations shall be earmuffs also.

7.8.0

Area where painting is carried out, as well as materials are stored shall be clean, After work, the areas shall be cleared of all scaffoldings, balance materials etc. in order to prevent fire hazards and hinder fire fighting operations.

7.9.0

Painting materials shall be stored and painting and blasting operations shall be carried out only in areas where fire fighting equipments/vehicles and personnel evacuation vehicles can have easy access. In areas where such easy access is not available suitable precautions are to be ensured.

8.0.0

INSPECTION

7.0.0. SAFETY 7.1.0. Sufficient safety precautions shall be taken to ensure protection of Personnel, equipments, piping structures and buildings in the vicinity, where painting materials are stored and painting and blasting operations are carried out.

PAGE 5 OF

8.1.0. All painting materials and related items shall be inspected to check the suitability of the same for the specified purposes. 8.2.0. Painting surfaces are to be inspected after cleaning operation, to ensure that the surfaces are fit for painting. 8.3.0. Finished surfaces shall be checked for uniformity in colour, finish and appearance as well as for defects.

FACT ENGINEERING AND DESIGN ORGANISATION

02ES023/97

PAINTING

ENGINEERING SPECIFICATION

8.4.0. Thickness of each coat of paint shall be checked after curing time. The total thickness of multiple coats shall be as specified in the data sheets/piping line schedules/painting schedules. 8.5.0. Paint thickness gauge shall be either mechanical or electronic. The gauges shall be calibrated regularly. Defective gauges shall not be used. 8.6.0. Absence of paint thickness gauge shall not be made for each eqpt/line/structure separately. 8.7.0. A detailed quality / inspection report shall be made for each eqpt / line / structure separately 9.0.0. GUARANTEE Guarantee shall cover materials and workmanship. 10.0.0. CODIFICATION MATERIALS

OF

PAINTING

10.1.0. Primers A.01 A.02 A.03 A.04 A.05 A.06

Synthetic Zinc Phosphate Primer Epoxy based Zinc Phosphate Primer Epoxy based Zinc Rich Primer Alkyd High Build Zinc Phosphate Primer Inorganic Zinc Silicate Primer Chlorinated Rubber based High Build Zinc Phosphate Primer

10.2.0. Finish Paints B.01 B.02 B.03 B.04 B.05

Epoxy Resin based Enamel Epoxy Resin based Micaceous Iron Oxide Paint Epoxy Resin based High Build Paint Coal Tar Epoxy Resin based Paint Chlorinated Rubber Paint

PAGE 6 OF

13

C.01

Nontoxic Inert Coating for drinking water tanks C.02 Acid Alkali and Heat Resisting Coating 10.4.0. Heat Resistant Paints D.01 D.02

Dual Pack Aluminium Paint (upto 250o C) Single Pack High Temperature Silicon Aluminium Paint (upto 600o C)

10.5.0. Polyurethane Coating. (For low temp. application) E.01 E.02

Two-Pack Polyurethane Holding Primer High Build Polyurethane Coating

10.6.0. General Purpose Paints F.01 F.02 F.03

Synthetic Resin based Enamel Chemical Resistant Enamel Alkyd, Antiskid Abrasion Resistant Synthetic Floor Paint

10.7.0. Special Applications G.01 G.02 G.03

Bituminous Mastic Coating Asphalt doping as per IS 10987 App-B Thermocolour Paint

10.8.0 As an alternative, in place of one coat of E.01 – Two pack Polyurethane Holding Primer, one coat of Epoxy Zinc Phosphate Primer A02 (20 microns) followed by one coat of High Build Epoxy containing Micaceous Iron oxide-Bo2 (20 microns) shall be applied before applying finish paint E02-High build Polyurethane coating. 11.0.0 SCHEME OF PAINTING 11.1.0. Scheme of painting of equipment, piping, structures and other items shall conform to class 1, class II or class III as specified in the equipment data sheet/ piping line schedule/ painting schedule/ structural drawings. 11.2.0 Representation of painting

10.3.0. Bituminous Coating FACT ENGINEERING AND DESIGN ORGANISATION

02ES023/97

PAINTING

ENGINEERING SPECIFICATION

Requirement of painting of an item shall be indicated in respective drawings/ data sheets/ line schedule/ painting schedule as follows. Indicate primer or finish or both as requiredfollowed by subclass indicated in Table 1, Table 2 or table 3 as the case may be. Eg Primer Finish Primer & Finish Primer Primer & finish Primer Finish Primer & Finish

Class I

(1)L

Class I

(1)L

Class I

(2)M

Class II

(2)O

Class II

(3)O/P

Class III

(1)

Class III

(1)

Class III

(3)

PAGE 7 OF

13

12.0.0 COLOUR CODING AND MARKING FOR PIPING 12.1.0 In addition to the requirements of painting as per 11.0 the finish painting of the piping shall have the specified colors as per Table 4 – Color coding for pipes, for purposes of identification of service. 12.2.0 All pipes and pipe lines covered under 1.7 shall be provided with “Markings” such as color bands, hazard markings, line identification markings, flow arrow markings etc. at specified locations/intervals and dimensions as indicated in Table 5 – Marking of pipes.

*******************

FACT ENGINEERING AND DESIGN ORGANISATION

02ES023/97

PAINTING

ENGINEERING SPECIFICATION

PAGE 8 OF

13

TABLE 1 – CLASS I – Pressure Vessels, Heat Exchangers, Reactors, Towers, Tanks and Piping Sl. No.

SERVICE CONDITIONS

OPERAT ING TEMP.

PAINT SUBCLASS

Type

1

UN INSULATED NON CORROSSIVE ATMOSPHERE UN INSULATED CORROSSIVE ATMOSPHERE INSULATED CORROSSIVE ATMOSPHERE

=/< 15 =/< 65 =/< 125 =/< 400

(1) L (1) N (1) M (1) H

=/< 15 =/< 65 =/< 125 =/< 400 =/< 15 =/< 65 =/< 125 =/< 400 INSULATED =/< 15 CORROSSIVE =/< 65 ATMOSPHERE =/< 125 =/< 400 SUPPORTS =/< 15 FOR ALL =/< 65 EQPTS.(INSUL =/< 125 ATED/UN =/< 400 INSULATED) EQPT. AND =/< 15 STRUCTRURE =/< 65 S SUBJECTED =/< 125 TO SALINE =/< 400 ATMOSPHERE UN INSULATED

2

3

4

5

6

PRIMER *DFT

Type

E.01 A.01 D.01 D.02

No.of coats 1 2 2 2

*DFT

E.02 F.01 D.01 D.02

No.of coats 2 2 2 2

30 20 20 20

(2) L (2) N (2) M (2) H (3) L (3) N (3) M (3) H (4) L (4) N (4) M (4) H (5) L (5) N (5) M (5) H

E.1 A.06 A.02 D.02 E.01 A.04 D.01 D.02 E.01 A.06 D.01 D.02 E.01 A.01 D.01 D.02

1 2 2 2 1 2 2 2 1 1 1 1 1 2 2 2

30 20 20 20 30 25 20 20 30 30 30 30 30 20 20 20

E.02 B.05 B.02 D.02 E.02 F.01 D.01 D.02

2 2 2 2 2 2 2 2

20 20 20 20 30 20 20 20

(6) L (6) N (6) M (6) H

E.01 A.06 A.02 D.02

1 2 2 2

30 20 20 20

E.02 B.05 B.01 D.02

2 2 2 2

30 30 30 20

* DFT – Dry film Thickness per coat microns Notation: L – N – M– H –

FINISH

Low Temperature Normal Temperature Moderate Temperature High Temperature

:

FACT ENGINEERING AND DESIGN ORGANISATION

30 20 20 20

02ES023/97

PAINTING

ENGINEERING SPECIFICATION

PAGE 9 OF

13

TABLE 2 – CLASS II – OTHER EQUIPMENTS PRIMER PAINT SUB CLASS

Sl. No. TYPE OF ITEM

1

2 3 4 5

6

7

8 9 10

11

Chimneys,Stacks, Furnaces,heaters (fired and unfired)operating Temp upto450o C D.M.Water Storage Tanks Fresh Water/fire Water Storage Tanks Drinking Water Storage Tanks Acid/alkali Storage Tanks Storage Tanks/Vessels for Petroleum Products Floating Roof Tanks:Inside of shell, top of bottom plate,topside and underside of deck, inside of pontoon Underside of Bottom Plate of Tanks Underground Tanks (buried) Below Ground (submersible) Tanks Secondary Reformer&Simila r Eqpt.(Thermo colour paint) *DFT : ** : Notation:

FINISH

Type

No.of coats

*DFT

Type

No.of coats

*DFT

Outside

(1)

A.05

2

25

D.02

2

20

Outside Inside Outside

(2)O (2)P (3)O

A.01 A.03 A.01

2 2 2

20 35 20

F.01 B.03 F.01

2 2 2

25 35 25

Inside Outside Outside

(3)P (4)O (4)P

A.03 A.01 A.01

2 2 2

35 20 20

B.04 F.01 C.01

2 2 3

75 25 20

Outside

(5)

A.04

2

30

C.02

3

25

Outside

(6)O

A.04

2

50

D.01

2

25

Inside

(6)P

A.02

2

30

B.03

2

75

Outside

(7)O

A.04

2

50

D.01

2

25

(7)P

A.02

2

30

B.03

2

75

(7)Q

A.01

2

25

(8)

A.01

1

20

G.01

1

80

Outside

(9)

A.01

1

20

G.02

Outside

(10)

A.06

2

35

B.05

3

35

(11)

G.03

2

**

G.03

1

**

Dry Film Thickness per coat microns As per Manufacturer’s recommendations O- Outside P-Product Side Q-Specified Side

FACT ENGINEERING AND DESIGN ORGANISATION

02ES023/97

ENGINEERING SPECIFICATION

PAINTING

PAGE 10 OF

13

TABLE 3 – CLASS III – MISCELLANEOUS

Sl. TYPE OF ITEM No.

1

Steel structures, Platform Supports

PAINTING SUB Type CLASS

PRIMER No. of *DFT coats

FINISH Type

No.of coats

*DFT

(1)

A.04

2

20

B.01

2

25

2

Chequered Plate,Floorplanks&Gang ways

(2)

A.04

2

20

F.03

2

25

3

Handrails Posts,Railings,Ladders and Stairways

(3)

A.04

2

20

B.01

2

25

* DFT – Dry Film Thickness per coat microns

FACT ENGINEERING AND DESIGN ORGANISATION

02ES023/97

ENGINEERING SPECIFICATION

PAINTING

PAGE 11 OF

13

TABLE 4 – COLOUR CODING FOR PIPES Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

Identification Ground / Finish Colour Instrument Air0 Sky Blue Service Air Sky Blue Plant Air Sky Blue Cooling Water Sea Green Service Water Sea Green Demineralised Water Sea Green Boiler Feed Water Sea Green Steam Condensate Sea Green Boiler Blow Down Sea Green Turbine condensate Sea Green Process Condensate Sea Green Low Pressure Steam Silver Grey Medium Pressure Steam Silver Grey High Pressure Steam Silver Grey Very High Pressure Silver Grey Steam Naphta Liquid Light Brown Naphta Vapour Light Brown Fuel Oil Light Brown Antifoam Solution Black Phosphate Black Hydrazinc Black Waste Water Black Oily Water Black Ammonia Liquid Dark Violet Ammonia Water Dark Violet Ammonia gas Dark Violet MDEA Solution Dark Violet Process Vent Canary Yellow Carbondioxide Canary Yellow Hydrogen Canary Yellow Nitrogen Canary Yellow LPG Canary Yellow Fuel gas Canary Yellow Process Gas Canary Yellow Synthesis Gas Canary Yellow Effluent Black Drinking Water Sea Green Service

Colour Band - 1

Colour Band - 2

White Light Brown French Blue French Blue French Blue Light Orange Light Brown White White Black Light Orange Light Brown Signal Red Signal Red

Signal Red French Blue Signal red French Blue

French Blue French Blue White Sea Green Signal Red Signal Red Sea Green White French Blue French Blue French Blue Black Light Grey Light Grey Signal Red Black French Blue Light Brown Sea green White Sea Green Light Orange

White Sea Green Signal Red Sea Green Canary Yellow White Signal Red Signal Red -

FACT ENGINEERING AND DESIGN ORGANISATION

02ES023/97

PAINTING

ENGINEERING SPECIFICATION

PAGE 12 OF

13

TABLE 5 – MARKING FOR PIPES 1.0. GROUND COLOUR UNIT OF MEASUREMENT Insulated Line – all (excludes buried line) 1.1. Un-insulated Lines–Stainless : Ground colour for a length Per Marking as per para 6.0 Steel,GI ,Alloy steels & of 2 meters below including pipe supports Other non-ferrous pipelines (excludes buried line) ___________________________________________________________________________ 1.2. Un-insulated carbon steel : Ground colour applied Run length in Meters along Lines (excluded buried throughout entire length centreline including Markings Lines) as per Para 6.0 below & pipe supports ___________________________________________________________________________ 2.0. COLOUR BANDS MARKINGS Colour band(s)and its width,Band 2 downstream of Band 1(ie.after band 1 along the direction of flow) Pipe size NB (D-pipe size in inches) 80 NB and below Above 80 NB(3”) up to 100 NB(4””) Above 100 NB(4”) up to 300 NB(12”) Above 300 NB(12”)

Band 1 mm 75 D x 25 D X 20 D x 15

B and 2 mm ¼ of Band 1 (Rounded to nearest mm)

the

HAZARD Diagonal strips of Black and golden Yellow as per IS2379 superimposed on MARKINGS the ground color. If color bands exists,the hazard marking shall be painted Downstream of the bands (ie. after bands in the direction of flow) 3.0.

LINE IDENTIFICATION MARKINGS

Color shall be Black or White to contrast with the color on which they are painted. It shall consist of Line No., Line size, Fluid code & Pipeline Spec. No. The lettering dimensions Shall be as per IS2379.

4.0.

FLOW ARROW MARKINGS

Color shall be Black or White to contrast with the color on which they are painted. The dimension of the arrow shall be as follows and is based on the size of the pipeline.

d

a c

b

a b c d

150NB & below 65 30 95 20

FACT ENGINEERING AND DESIGN ORGANISATION

200NB & above 90 50 125 30

02ES023/97

ENGINEERING SPECIFICATION 5.0.

PAINTING

PAGE 13 OF

13

LOCATION OF MARKINGS Marking includes 2M long ground color, color band(s), hazardous marking, Line No. & flow direction arrow which shall be located at the following points with proper visibility as per IS2379. a. b. c. d. e.

Battery Limit Points Either side of walls & dyke walls For long yard piping – at 30M interval Inter-section on pipe bridge Any other location indicated by the Engineer-in-charge at site

6.0.

PIPE SUPPORTS

6.1.

This includes base springs, hanger springs, shoes and trunnions etc. and excludes pipe bridge structures, platform, equipment support structures and such structures which do not actually support the pipeline.

6.2.

The painting of pipe supports forms part of the pipelines and a separate rate will not operate.

6.3.

The

painting specification for pipe supports shall be same as that for pipe ground colour.

****************

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION

02ES042/97

COLD INSULATION

PAGE 1 OF 26

CONTENTS

PRPD.BY:- CK

1.0.0

SCOPE

2.0.0

INSULATION MATERIALS

3.0.0

ANCILLARY MATERIALS

4.0.0

INSULATION THICKNESS

5.0.0

APPLICATIOIN

6.0.0

PIPING INSULATION

7.0.0

MACHINERY ITEMS

8.0.0

INSTRUMENTS & MISC. ITEMS

9.0.0

INSULATION CAST - IN - SITU

10.0.0

SAFETY

11.0.0

GUARANTEE

12.0.0

APPLICATION DETAILS

CHKD.BY:- GPN

APPRD. BY:- KV

FACT ENGINEERING AND DESIGN ORGANISATION

ISSUED ON:- 24-7-97

ENGINEERING SPECIFICATION

02ES042/97

COLD INSULATION

1.1.0 SCOPE This specification covers the requirements for the supply and application of external, self extinguishing type thermal insulation of equipment and piping for cold service conditions. 1.1.0 REQUIREMENT OF COLD INSULATION 1.1.1 Requirement of cold insulation of any equipment or piping shall be as specified in any of the following documents. a. Equipment data sheets / drawings b. Piping line schedule c. Design basis for package items d Insulation schedule 1.1.2

Cold insulation is required to be provided on Pressure vessels, Heat Exchangers, Columns, Tanks other process equipment and Piping to meet the following requirements. a.. To maintain process / operating temperature. b. To prevent ingress of heat from external source/atmosphere. c. To avoid surface condensation. 1.1.3 Insulation requirement to maintain process/operating temperature shall be as indicated in documents referred to in 1.1.1. 1.1.4 Insulation for preventing ingress of heat from external source/atmosphere and to avoid surface condensation shall be provided on all equipment and piping operating below 20o C. 1.2.0 Limits of Application. 1.2.1 The following items shall not be insulated unless otherwise specified. a.

Bonnets of valves above packing glands

b.

Nameplates and data plates of equipment.

1.2.2

PAGE 2 OF 26

All attachments and projections such as supports, structures attached to equipment pipe hanger supports, Instrument lead lines, branch lines like vents and drains and instrument connections connected directly to cold insulated equipment and piping shall be cold insulated up to a distance of 5 times the adjoining insulation thickness.

2.0.0 INSULATION MATERIALS 2.1.0 The material of insulation shall be as specified in the documents indicated in 1.1.1 and shall be one of the following. a. Polyurethane foam b. Expanded Polystyrene 2.2.0 Material of insulation shall be nonabsorbent with a closed cell structure to ensure non-permeability of moisture / water vapour. 2.3.0 Material of insulation shall be fungus and vermin proof. 2.4.0 Insulation material shall not contain chemicals, which may be harmful to the equipment or piping or to the protective coating at ambient or service temperatures in wet or dry condition. 2.5.0 Insulation material used for austenitic steel equipment and piping shall be free from water-soluble chlorides and other harmful chemicals. 2.6.0 POLYURETHANE FOAM (PUF) 2.6.1 Polyurethane foam (PUF) may be used for insulation of equipment and piping either as preformed sections or cast-in-situ. 2.6.2 Polyurethane foam shall be of rigid preformed cellular urethane foam and self-extinguishable type in accordance with ASTM-C 591, Type II, Gr.2.

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION

2.6.3 The foam shall be formulated in such a way that it shall be of selfextinguishing quality which shall not cause fire to spread under any circumstances.

2.7.5

2.6.4 The finished foam, in the form of sections, slabs or cast-in-situ, shall be of uniform closed cell structure, free from unreacted material, shrinkage and distortion. 2.6.5 Density of finished foam shall be approximately 45 Kg/m3. 2.6.6 Thermal conductivity of the finished polyurethane foam shall not exceed 15 Kcl/hr deg C at 10 deg C mean temperature after ageing. 2.6.7 Closed cell content of finished PUF shall be at least 95% by volume. 2.6.8 Maximum permeance of finished PUF shall be 4.0 gms/m. 24h.mm Hg. 2.6.9 Resistance of 10% compression of finished PUF at ambient temperature shall be 1.5 Kg/cm 2.7.0 EXPANDED PLYSTYRENE (EPS) 2.7.1 Expanded polystyrene (EPS) may be used for insulation of equipment and piping in the form of preformed sections or slabs. 2.7.2 Expanded polystyrene shall be of selfextinguishing type with closed cell structure in accordance with IS-4671 type 2. 2.7.3 Finished EPS shall be free from shrinkage distortion and unreacted materials. 2.7.4 Density of finished EPS shall be given below: Preformed sections Slabs

02ES042/97

COLD INSULATION

20 to 22 Kg/m3 18 o 20 Kg/m3

PAGE 3 OF 26

Thermal conductivity of finished EPS shall be as given below: ---------------------------------------------Density Thermal conductivity Kcal/m.hr. oC 0oC 10oC ---------------------------------------------18 0.028 0.031 20 0.027 0.030 22 0.026 0.029

2.7.6 Maximum permeance of finished EPS shall not be more than 4.0 gms/m. 24 hr.mm.Hg. 2.7.7 Finished EPS shall be free from leachable chlorides. 3.0.0 ANCILLARY MATERIALS 3.1.0 Wire netting; Lacing & Stitching Wire netting of preformed sections and slabs shall be of 24 swg x 20 mm GI. Lacing and stitching wires shall be of 20 swg and 22 swg GI respectively. 3.2.0 BANDS Aluminium bands of size 20mm width x 24 swg shall be used for securing insulation sections and slabs in place. 3.3.0 METAL CLADDING Commercial quality aluminium jacketing conforming to IS 737 shall be used for all equipment and piping. Thickness of cladding sheets shall be as indicated in table. 1. 3.4.0 SELF TAPING SCREWS Self tapping screws to be used for securing the metal cladding shall be 6mm dia cadmium plated or galvanised, and best quality.

3.5.0

SEALING COMPOUND

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION

3.5.1

02ES042/97

COLD INSULATION

To ensure perfect water proofing, cladding joints shall be packed with sealing materials, which may either be in the form of bituminous mastic sealing compound or fibre based bituminous felt strips.

3.5.2 Sealing compound shall be suitable to withstand the temperature of insulation to seal the joints. 3.6.0 MASTIC BEDDING Insulating sections and slabs shall be bedded in non-setting mastic to eliminate air pockets. The same mastic shall be used for ensuring vapour tight joints between adjacent sections/slabs. 3.7.0 HARD SETTING PLASTER Hard setting plaster (mixture of sand & cement or asbestos & cement shall be applied over wire netting on piping subjected to foot traffic. 3.8.0 BITUMINISED SELF-FINISHING ROOFING FELT. Bituminised self-finishing roofing felt shall conform to IS 1322 Type 3 Gr. 1. [

3.9.0 VAPOR BARRIER 3.9.1 Sealing mastic for the vapour barrier shall be fire retardant mastic, bituminous emulsion mastic or elastomeric polymer mastic. 3.9.2 Instead of sealing mastic, aluminium foil of about 0.025mm (25 microns) thick glued to craft paper using polyethylene glue or aluminium foil (.025mm thick) coated with polyester may also be applied as vapour barrier. 4.0.0 INSULATION THICKNESS 4.1.0 Insulation thickness shall be as specified in the equipment data sheet/piping line schedule/insulation schedule. 4.2.0 For package items, the insulation thickness as per table 2 may be used as

PAGE 4 OF 26

a guidance for selecting the minimum thickness of insulation required. The vendor shall check the same for process adequacy. 5.0.0 APPLICATION 5.1.0 GENERAL 5.1.1 The surfaces to be insulated shall be thoroughly cleaned by wire brushing to remove dirt and loose scale. Equipment and piping which have received primer / painting shall be cleaned well, without disturbing the surface treatment already received. 5.1.2 Unprimed carbon and low alloy steel surfaces shall be thoroughly cleaned by wire brush and one coat (30 microns) of epoxy based zinc phosphate primer shall be applied before starting cold insulation. Sufficient curing time shall be allowed for surface treatment. 5.1.3 Stainless steel and other non-ferrous surfaces shall not be primed. 5.1.4 The equipment drawings indicate the extend of insulation and location of insulation supports. However, the insulation contractor shall recommend, furnish and install any additional supports and anchorage that may be required to adequately support the insulation. Field welding of clips and supports shall be carried out only with the prior approval of the Engineer-incharge. 5.1.5 All insulating and ancillary materials shall be new and unused and shall be free from contaminating materials, dust and dirt. 5.1.6 All insulation materials shall be stored in covered areas protected from moisture and dust. Insulation materials shall not be stacked directly on ground. Insulation materials showing any evidence of absorption of moisture shall not be used.

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION

COLD INSULATION

5.1.7 Insulation work shall be carried out only after hydrostatic testing of equipment / piping have been completed. 5.1.8 Insulation of flange joints shall be come only after they have been proved to be leak tight. 5.2.0 MULTILAYER INSULATION 5.2.1 When thickness of insulation exceeds 60mm, the insulation may be applied with multi layers, with all joints staggered. Each layer of insulation shall be secured by metallic banding. 5.2.2 All cracks and voids in the insulation shall be completely sealed by using the mastic bedding indicated in 3.6.0. 5.2.3 No. of layers to be employed shall determined as given below: Insulation thickness Up to 60 mm Up to 120 mm Above 120mm

No. of layers 1 2 3

5.3.0 VAPOR BARRIER 5.3.1 Vapour barrier shall be applied on insulation of all equipments at the outermost layer before metal cladding is applied. 5.3.2 Polyurethane foam and expanded polystyrene insulation shall be completely covered with a continuous vapour tight layer to prevent permeation of vapour into the insulating material. 5.3.3 A layer of sealing mastic shall be applied over the entire surface of the insulation, to obtain a thickness of 2 to 2.5 mm when completely dry. Over this coat while it is still wet a layer of open weave glass fibre cloth of 10 mesh size and 0.125 mm thick stretched with out any wrinkles or air pockets shall be laced with glass fibre threads. A final coat of sealing mastic shall be applied

02ES042/97 PAGE 5 OF 26

over the glass fibre mesh to obtain a thickness of 2.5 mm when dry. 5.3.4 Alternative type of vapour barrier as described in 3.9.2 may be applied instead of that given in 5.3.3, in which case all joints shall be completely sealed and shall leave an overlap of at least 100 mm. Sealing of joints shall be done by using airtight and waterproof adhesive tape. 5.4.0 WIRE NETTING & BANDING 5.4.1 Aluminium bands as specified in 3.2.0 shall be fixed over insulation blocks at an interval of 300 mm. 5.4.2 Before application of vapour barrier, the insulation sections and slabs shall be completely covered by wire netting, laced and stitched by using wire nets, lacing and stitching wire specified in 3.1.0. The bands shall be sufficiently tightened to keep the insulation sections/slabs firmly in place without deforming the insulation. 5.4.3 Protruding ends of the bands shall be cut off or turned down so as not to damage vapour barrier. 5.5.0 FILLING OF VOIDS 5.5.1 Polyurethane dust mixed with specified adhesive shall be packed tightly so as to fill voids and contractions on PUF insulation. 5.5.2 Blown bitumen mixed with polystyrene beads shall be used to fill voids and contractions in EPS insulation. 5.6.0 ALUMINIUM CLADDING 5.6.1 Vapour barrier of PUF or EPS insulation shall be protected by aluminium cladding specified in 3.3.0. 5.6.2 Aluminium cladding shall be bent to shape grooved & properly riveted by using pop rivets. 5.6.3 All joints of the cladding shall overlap aluminium of 50 mm and shall be arranged in such a way as to shed

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION

COLD INSULATION

water. Joints shall be offset between pieces. 5.6.4 Cladding shall be secured to aluminium bands of size 20 x 3 mm. Which are provided at a gap or 450 mm along the circumference. 5.6.5 All joints in the cladding shall sealed water tight by using seating compound or tapes as described in 3.5.0. 5.6.6 Jacketing for dished heads shall be fabricated radial segments with an overlap of 50mm. The sheeting shall be secured in position by radial tensioned metallic bands stretched over the heads. One end of each band is anchored to the circumferential band with shell, while the other is fastened to a floating ring fabricated in the form of a ring. The sheet metal bands may be held in place by using pop rivets. 5.7.0 FLASHING 5.7.1 Openings in metal jackets for nozzles, manholes, brackets shall be cut as close as possible for a smug fit. 5.7.2 All openings through insulation finish shall be flashed weather tight by an approved sealant particularly where connections are not insulated. 5.7.3 Skirt supported vessels shall have the skirt insulated inside and outside for at least 600 mm below the tan gent line. 5.7.4 Unless otherwise specified no insulation shall be applied to the inside of the skirt, which are externally, fire proofed. 5.7.5 For leg-supported vessels, insulation shall be provided to a length of at least 5 times the insulation thickness minimum. 5.8.0 VERTICAL VESSELS 5.8.1 Cylindrical Shell 1. Slabs/sections in handy sizes shall be applied resting on to the supports with joints tightly butted, staggered and

02ES042/97 PAGE 6 OF 26

adhering to each other with specified adhesives. 2. The slabs/sections are to be secured in position by circumferential metallic bands at an interval of 300mm. When multi layer insulation is applied each layer shall be banded separately. 5.8.2 Top Heads 1. Insulating material shall be properly shaped and tightly pressed on the top head. 2. The insulation shall be held in position by using metallic bands one end of which shall be fastened to the floating ring and the other end shall be anchored to the circumferential band laced on shell near the head. 3. Radial bands shall be spaced at 300 mm gap measured along the circumference of the vessel. 4. The final layer of insulation shall be held in position by metallic wire net laced at the top vortex nozzle by about two to three loop of 10 swg galvanised iron wire and the wire net over the insulation of he shell close to the head. 5. When there are no top vertex nozzles, the insulation shall be held in position by wire netting and metallic bands stretched over the head and anchored on the cylindrical section close to the head by circumferential metallic band on the shell near the head. 5.8.3 Bottom Heads 1. Preformed and shaped insulation sections shall be used for insulating the bottom head. 2. Preformed and shaped insulation sections shall be held in place in the same manner as for top heads. 3. While one end of the metallic bands shall be fastened to floating ring if a bottom vortex nozzle is present, the other end shall be anchored to the

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION

insulation support ring provided inside the skirt support. 4. Radial bands shall be spaced at 300mm pitch measured along the circumference. 5. In case of absence of a bottom vortex nozzle, the metallic bands shall be stretched across the bottom head and anchored at the ring inside the skirt. 5.9.0 HORIZONTAL VESSELS 5.9.1 Insulation of horizontal vessels shall be carried out by using preformed and shaped insulation blocks/sections. 5.9.2

Insulation material shall be held in place by using metallic bands a spacing of 300 mm.

5.9.3

Final layer of insulation shall be provided with netting, laced and stitched. Each layer of insulation shall be banded separately and bands of successive layers shall be staggered.

5.9.4

5.9.5

02ES042/97

COLD INSULATION

Insulation blocks/sections shall be held in position by metallic bands at radial pitch of 300mm on the heads and anchored to the circumferential metallic bands on shell near the head.

5.10.0 HEAT EXCHANGERS 5.10.1 Insulation of vertical heat exchangers shall be carried out in the same manner as in 6.0.0. 5.10.2 Insulation of horizontal heat exchangers shall be carried in the same manner as in 7.0.0. 5.10.3 Exchanger channels and channel covers including bolting flanges shall be insulated with removable aluminium covers lined with insulation sections/blocks of specified thickness. 5.11.0 SPHERICAL VESSEL 5.11.1 Shaped insulation block shall be used for spherical vessels. 5.11.2 All joints shall be sealed well by approved joint sealant.

PAGE 7 OF 26

5.11.3 Inner layers of insulation shall be held separately in place by metallic bands at 300 mm pitch at equator. 5.11.4 The bands shall be tied up with floating rings of 20mm O/D made of 15 SS rod at the poles of the sphere. 5.11.5 The bands on the successive layers shall be staggered and the clip ends are to be bent and recessed in to the insulation. 5.11.6 Outer layer of insulation shall be secured in place by wire netting, laced and stitched together. 5.12.0 STORAGE TANKS 5.12.1 Insulation of storage tank shell shall be carried out in the same manner as described in 6.0 5.12.2 Where tank fabricator has provided support rings and vertical flats on the tank shell, the insulation contractor shall provide additional rings at a pitch of 900 mm. These additional rings shall be tack welded only to the support rings and vertical flats. No welding shall be permitted on the tank surface. 5.12.3 Metal cladding of tank shell shall be with 22 swg corrugated aluminium sheet. All points shall be staggered by 300mm and shall be sealed water proof with approved sealing material. 5.12.4 Tank Roof 1.Tank roof shall be thoroughly cleaned of all dirt and rust and other contaminants. 2.Preformed insulation sections/slabs shall be laid over one coat of adhesive mastic and pressed well. All joints shall be sealed with adhesive mastic to make it airtight. 3. When multi layer insulation is applied of successive layers shall be staggered and sealed with adhesive mastic. 4. Each lay of insulation shall be secured with bands and wire netting laced and stitched as detailed in 5.8.2.

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION

6.1.7

At un-insulated flanges, insulation shall be terminated at suitable distance from the flange so that the flange bolts can be withdrawn without disturbing the insulation.

7. Apply a 20mm thk hard setting nonconductive plaster made from asbestos fluff and Portland cement troweled to a smooth and even finish.

6.1.8

In case of vertical piping, insulation supports shall be installed by the insulation contractor. These shall consist of spacer rings at 4 metres intervals clamped to the pipes.

6.1.9

Insulation of piping shall be complete with mastic bedding, sealing compound, vapour barrier, filling of voids and metal cladding as described earlier in the specification.

6.0.0 6.1.0 6.1.1

PIPING INSULATION GENERAL External surfaces of pipes shall be cleaned well with wire brush (CS brush for CS pipes and SS brush for SS pipes) to remove all dirt rust and contaminating material and wiped well.

6.1.2

If painting is provided for specific reasons the insulation contractor shall not carry out any harsh cleaning and shall ensure that painting is undisturbed.

6.1.4 6.1.5

6.1.6

PAGE 8 OF 26

5. Vapour barrier shall be applied as specified in 5.3.0. 6. Fix a shed water shroud constructed from 20 swg GI plain sheets at the periphery of the tank.

8. When hard setting plaster is completely dry apply a standard 4 course bitumen felt as per IS 1346. Aluminium cladding shall be applied over this.

6.1.3

02ES042/97

COLD INSULATION

All pipes and supports shall be permanently set before commencement of insulation. Disturbed pipes and supports shall be restored to their original location and alignment when insulation is complete. All insulation shall be applied when piping is at ambient temperature. Spacer rings for supporting metal cladding shall be installed by the contractor. Insulation in the form of preformed pipe sections shall be applied over the pipe without spacer rings. On top of each layer wire netting shall be applied and tightly butted against each other so that the wires interlock both longitudinally and circumferentially. The wire net joints shall be stitched with 20 swg soft galvanised iron wire.

6.1.10 Insulation of flanges and valves shall be provided only when specifically mentioned in the line schedule/work order. When specified, removable covers shall be provided over all flanges and valves. The insulation shall be preformed, filled in aluminium sheet boxes, and fitted with quick release clips. 6.2.0

INSULATION OF PIPING FOR FOOT TRAFFIC

6.2.1

After application of insulation including vapour barrier the insulation sections are to be held together with GI wire netting and joints laced with GI wire. Wire netting shall be held together with 20mm wired hoop iron bands at 300mm spacing.

6.2.2

6.2.3

Apply hard setting plaster as per 3.7.0 of 20mm thick-troweled smooth.

6.2.4

After the hard setting plaster has dried wrap bituminised self-finishing roofing felt over the plaster with an overlap of 50mm both longitudinally and circumferentially.

6.2.5

The roofing felt shall be secured with 24 swg x 20mm GI wire netting and all joints are to be laced with 20 swg GI wire.

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION

6.2.6

Apply 3mm thick bituminous emulsion mastic compound for water and weather proofing.

6.2.7

When bitumen emulsion has completely dried the surfaces shall be painted with bitumen based aluminium paint.

6.3.0 6.3.1

6.3.2

6.3.3 6.3.4

02ES042/97

COLD INSULATION

PIPING INSPECTION WINDOWS Plug type inspection windows shall be provided on all insulated pipelines having size 50 mm and above.

item to be insulated for the approval of Engineer-in-charge. 8.0.0

INSTRUMENTATION & MISCELLANEOUS ITEMS

8.1.0

Drain and vent piping up to the first valve on insulated equipment shall be insulated with similar type of insulation and finish as the equipment to which it is attached.

8.2.0

Headers, branch lines sample connections and pipelines to instruments shall be insulated with similar type of insulation and finish as the connected piping.

8.3.0

The thickness and type of insulation for all lines mentioned before shall be determined from piping like schedule for corresponding temperature and pipe sizes. Thickness of insulation for the parts not mentioned shall be as specified by Engineer-in-charge.

9.0.0 9.1.0

INSULATION CAST-IN-SITU Large vessels and equipment may be insulated using polyurethane foam, foamed in situ.

The size of the inspection windows shall be as indicated below: Pipe dia (mm) Window dia (mm) 50 35 80 45 100 75 150 and above 100 Inspection windows shall be provided at the bottom of the pipelines. There must be at least one inspection window within a span of 10m.

PAGE 9 OF 26

6.3.5

At least 50% of the bends shall be provided with inspection windows.

6.3.6

In case of critical pipelines, more number of inspection windows may be provided at the discretion of the Engineer-incharge.

9.2.0

Sheet metal covering of inspection windows shall be of the same gauge as that of insulation cladding. These covers are to be fixed on with 6 mm self-tapping screws.

Before commencement of foaming-insitu, the contractor shall demonstrate the foaming procedure to the approval of Engineer-in-charge to check for the presence of voids after formation.

9.3.0

3 samples of PUF per shift shall be foamed in transparent polyethylene bags in presence Engineer-in-charge. Insulation work shall commence only after the approval of samples by the Engineer-in-charge.

9.4.0

Both the surface of equipment to be insulated and the cladding shall be free of rust, dirt and other contaminating matters.

9.5.0

The sheet metal cladding shall be adequately strapped and braced to withstand pressures developed during foaming, without distortion or failure. All joints of cladding shall be made leak

6.3.7

6.3.8

7.0.0

The plug shall be of perfect fit into the inspection window and shall ensure leak tightness. MACHINERY ITEMS in general PUF/EPS filled removable prefabricated sheet metal boxes shall be adopted for insulation of machinery items. The contractor shall submit insulation details of individual items of equipment depending on the nature of

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION

9.6.0 9.7.0

02ES042/97

COLD INSULATION

PAGE 10 OF 26

proof by using impermeable mastic sealing compound. Air escape holes provided in the cladding shall be sealed well after foaming.

Table 1 Thickness of Aluminium cladding sheets Table 2 Thickness for Cold Insulation

The annular space between the equipment and the cladding shall not be less than the thickness of insulation specified and shall be maintained uniform throughout by use of performed Polyurethane spacers, which will remain embedded in foam.

Fig.1

Insulation of Vertical Vessels

Fig.2

Insulation of Exchanger Shell & Head Expansion joint for Rigid Insulation

10.0.0 SAFETY The insulation contractor shall provide adequate protective appliances, like gloves, masks, glasses and clothing to workmen carrying out the insulation work for protection against any hazardous / toxic chemicals and gases. Sufficient for protection methods / gadgets shall also be deployed at the place of insulation. 11.0.0 GUARANTEE 11.1.0 The insulation contractor shall furnish authentic test certificates to confirm that all materials offered conform to the requirements of this specification and standards mentioned therein. 11.2.0 All insulation works shall be guaranteed against defective materials and bad workmanship for the period specified in enquiry / order.

Fig.3 Fig.4

Support for Vertical Insulated Piping

Fig.5 Fig 6 Fig.7

Welded Elbow Insulation Tee Insulation Bottom Head Insulation for Vertical Vessels

Fig.8 Fig.9 Fig.10

Flange Insulation Valve Insulation Flashing at Nozzles & Other Projections.

Fig.11 Fig.12 Fig.13

Uninsulated Flange Tank shell insulation-Details Support detail for metal covering of insulation.

Fig.14 Fig.15

Man hole Insulation Details of Corrugated sheet overlapping

Fig.16

Details of Tank Roof Insulation supports. Details of Tank Top setting Plaster Finish

Fig.17 12.0.0 APPLICATION DETAILS Refer the following details attached to this specification for application of insulation of various parts.

Fig.18 Fig.19

*******************

FACT ENGINEERING AND DESIGN ORGANISATION

Single layer Insulation for Piping Multiple layer Insulation for Piping.

02ES042/97

COLD INSULATION

ENGINEERING SPECIFICATION

PAGE 11 OF 26

TABLE 1 – THICKNESS OF ALUMINIUM CLADDING SHEETS Size (mm) Or Dia

Item

< / = 350 NB Equipment

Piping

Type of aluminium sheeting Vertical Other portions 24 SWG plain 24 SWG plain

>350 NB

22 SWG Corrugated

24SWG plain

Tanks

22 SWG Corrugated

22 SWG plain for roof and 24SWG plain for other parts

< / = 350 NB

24 SWG plain

22 SWG plain

> 350 NB Valves, flanges etc.

24 SWG plain

24 SWG plain

24 SWG plain

22 SWG plain

TABLE 2 – THICKNESS OF COLD INSULATION Nom: Dia < / = 20 65 80 150 400 500 900 Above 900

-40 60

Insulation Thickness (mm) for Temperature Deg.C -30 -20 -10 0 10 60 60 50 50 40

70 80 90 100 110 120 130

70 80 90 100 110 120 130

70 80 90 100 110 120 130

60 70 80 80 80 80 80

60 70 80 80 80 80 80

FACT ENGINEERING AND DESIGN ORGANISATION

20 40

50 50 50 50 50 50

50 50 50 50 50 50

50

50

iso2.sty

ENGINEERING SPECIFICATION

ERECTION OF STATIC EQUIPMENT

PAGE 1 OF 5 h. Strength calculation sheet including stress diagram of gin pole/ boom derrick, guy ropes and anchor points. i. Orientation and position and strength of lifting lugs or lifting beam. j. List of temporary equipment and tools to be prepared. k. L ist of prin ciple comp onen ts of g in pole/boom derrick. l. Transportation plans of gin pole/ boom derrick construction equipment and special vehicles. m. Installation plan and progress schedule of gin pole/boom derrick. n. Electric power to be consumed during installation.

CONTENTS 1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 6.0.0 7.0.0 8.0.0 9.0.0 10.0.0

SCOPE REFERENCES GENERAL PLANNING CONSTRUCTION EQUIPMENT INSTALLATION ALIGNMENT GROUTING LOOSENING SLIDE END ANCHOR BOLT INSPECTION RECORD

—————————————— 1.0.0

SCOPE This specification covers the requirement for the installa tion, alignment and grouting work of static equipments like towers, vessels and heat exchangers.

2.0.0

REFERENCES The requirements contained in the latest editions of the following standards shall form an integral part of the requirements of this specification in the manner and to the extent specified herein. ANSI B 30.5 Safety Code for Crawler, Locomotive & Track Cranes ANSI B 30.6 Safety Code for Derricks. ANSI B 30.9 Safety Standard for Slings. ANSI S 310

3.0.0

Specification for Design , Fabrication & Erection of Structural Steel for Buildings

GENERAL The installation work shall further comply with the requirements of the applicable codes or regulations in force at the locality of the job site.

4.0.0

PLANNING After investigating the job site but prior to commencing of the work, installation plans shall be made by considering the following items: a. Shape, dimension, weight, and material of equipment. b. Installation sequance of equipment. c. Transportation route of equipment. d. Strength and condition of unloading jetty. e. Installation procedure, including utilisation plan of gin pole, boom derrick, crane, construction equipment, and special vehicles. f. Work space around the installation area. g. Schedule of installation of each equipment.

PRPD. BY:

25ES201 / 94

CHKD. BY:

5.0.0

CONSTRUCTION EQUIPMENT

5.1.0 5.1.1

HOISTING EQUIPMENT Gin pole / Boom derrick Select the gin pole/boom derrick according to the shape, weight, and dimension of the equipment to be installed, and the surrounding condition. The gin pole/Boom derrick shall have ample height to lift the tallest equipment to be installed. The mast base of the gin pole/boom derrick shall be anchored securely. The erection plan of the gin pole/boom derrick shall be made by considering the following: 1. Site of Gin Pole/Boom derrick. Prior to starting the gin pole/boom derrick erection, the soil condition shall be investigated and a temporary concrete foundation shall be provided, if necessary. 2. Strength The gin pole/boom derrick shall be of a design to withstand all loads of equipment weight, d y na m ic fo rce s su ch as wind lo ad , o r earthquake load, etc. The design of the gin pole/boom derrick shall be in accordance with the AISC specifications. The loads shall not exceed the manufacturer’s rating with the recommended reeving. 3. Guy Rope All guy ropes of the gin pole shall conform to the following requirements: a. The gin pole of the double mast type shall have atleast eight guy ropes. For the single pole type, six guy ropes shall be provided. If the gin pole of the double mast type is to be used at an inclined position, at least two wire ropes shall be provided to limit the gin pole inclination. Preferably, the guy ropes shall be equally spaced around the mast. b. All guy ropes shall be stretched to have a uniform and ample slack. Guy ropes shall be installed so as not to interfere with other work or traffic. c. All guy ropes shall be fitted with a minimum

APPRD. BY:

FACT ENGINEERING AND DESIGN ORGANISATION

ISSUED ON: MAR ’94

ENGINEERING SPECIFICATION

ERECTION OF STATIC EQUIPMENT

of three cable clamps or equivalent at each connection to prevent slippage. The diameter of the usable guy ropes shall not be less than that specified in the installation plan. The safety factor of guy ropes shall comply with ANSI B 30.6. 4. Anchor Anchoring of winch, guy ropes etc. shall be accomplished by installing deadmen unless otherwise specified. Deadmen shall be placed so as not to interfere with eqpt foundations, underground facilities & structures. 5.1.2 Winch 1. The winch shall be located so that it does not obstruct passage of equipment nor prevent the operator from observing the signalman. 2. Anchors to the winch shall be provided to withstand the maximum force working on the winch. Brakes and clutches shall be protected from the weather so that a sudden rain fall, during lifting, shall not cause the load to slip or drop. 5.1.3 Mobile crane 1. All mobile crane operators shall be qualified by governmental or other equivalent authorities. A set of the manufacturer’s lift tables shall be placed conspicuously in the mobile crane operator’s cab at the job- site. The capacities given shall be adhered to strictly. Additional boom sections installed on the equipment shall be compensated by additional counterweights in accordance with the instruction manual. Timber mats and/or steel mats shall be provided for treads or tires considering the soil bear ing. Basically, outriggers and jacks shall be provided on the mobile crane to guard it against sudden tire failures and overturning while lifting heavy equipment. 2. All cranes shall be inspected in accordance with ANSI B 30.5 . When a risky condition is found, appropriate measures shall be taken immediately. Major items of inspection shall be as follows: a. All control mechanisms as to maladjustment. b. All control mechanisms as to excessive wear of components and contamination by lubricants or other foreign matter. c. All control mechanisms as to malfunction. d. Deterioration or leakage in air or hydraulic systems. e. Electrical apparatus as to malfunctions and signals. f. Crane hooks with deformations or cracks. g. Deformed, cracked, or corroded members in the crane structure and boom.. h. Rope reeving as to noncompliance. i. Ropes.

25ES201 / 94 PAGE 2 OF 5

5.2.0

WIRE ROPE, SLINGS, CHAINS AND FITTINGS 1. Wire Rope Wire ropes shall be of suitable size, grade and construction to withstand the maximum load imposed. Wire ropes in the main hoisting system shall be of ample length for the entire range of movement specified with at least two full wraps of the rope on the hoist drum at all times. Wire ropes shall be inspected in accordance with ANSI B 30.6. When any of the risky conditions listed below is found, the wire rope shall be removed from the sling service and appropriate measures shall be taken to improve the condition. a. In running ropes, six randomly distributed broken wires in one rope lay, or three broken wires in one strand in one rope lay. b. Wear of one-third of the original diameter of the outside individual wires. c. Linking, crushing, bird caging or any other damage resulting in distortion of the rope structure. d. Evidence of any heat damage from any cause. e. Reductions from nominal diameter of rope exceeding: 3/64 inch for diameters upto 3/4 inch inclusive. 1/16 inch for diameters 7/8 inch to 1-1/8 inches inclusive. 3/32 inch for diameters 1-1/4 inches to 1-1/2 inches inclusive. f. In standing ropes, more than two broken wires in one lay in sections beyond the end connection or more than one broke wire at an end connection. 2. Wire Rope and Sling Wire rope slings shall comply with ANSI B 30.9. The safety factor for wire rope slings of all grades shall be not less than five. 3. Chain All chains shall be forged or electric welded steel link type of the proper size for the loads to be lifted. Overloaded chains shall be discarded immediately. 4. Drum, Pulley and Sheave The diameter of the drum or pulley shall be not less than 20 times the rope diameter. The diameter of sheaves shall be not less than 10 times the rope diameter. 5. Fitting All hooks, swivel hooks, anchor shackles, swivel sockets, safety hooks, cable clamps, turnbuckles, and other attach ments shall be made of drop forged steel. 6. Safety Factor

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION

PAGE 3 OF 5 TABLE - 1 ITEM

MIN. SAFETY FACTOR

6.2.0 6.2.1 6.2.2

Hoist Rope Hoist Rope for Raising and Falling Boom

Wire Rope for Turning

3

Wire Rope or Guy Rope for Tension Wire Rope for Sling

5

6.0.0

INSTALLATION

6.1.0 6.1.1

ERECTION OF GIN POLE/BOOM DERRICK Inspection of gin pole components Prior to erecting the gin pole/boom derrick all winches, hooks, shackles, thimbles, wires, chains, etc., shall be inspected thoroughly as to material, capacity, wear and tear. Grounding The gin pole/boom derrick shall be equipped with grounding. Resistance of grounding shall be under 10 ohms. Assembly and disassembly The following precautions shall be taken in the assembly and disassembly of the gin pole. 1. During the assembly and disassembly operation of the gin pole/boom derrick only persons to be engaged directly in the work shall be admitted into the work area. 2. Only qualified operators for hoisting and slinging shall be assigned and a list of such operators shall be prepared and filled. Inspection after assembling Immediately after assembly and prior to starting the lifting of any equipment, the following parts of the gin pole/boom derrick shall be inspected carefully: 1. Gin pole/boom derrick members and connections thereof. 2. Anchor of winch. 3. Guy ropes as to number, tension and condition. 4. Wire ropes as to condition of wear and damage. 5. Hook, shackle, thimble and other hanging implements as to conditions of wear and damage. 6. All control mechanisms and other safety devices. 7. Electrical apparatus and controls of winch. Preventing accidents by guy rope For preventing accidents, all guy ropes shall be attached with red flags so that they will be recognizable from a distance.

6.1.3

6.1.4

6.1.5

PREPARATION OF SHIMS AND WEDGE Shims & wedges shall be made of carbon steel. In general shims & wedges shall be prepared by machining or grinding as indicated in Table 2. TABLE - 2

3.5

Wire Rope for Supporting Boom

6.1.2

25ES201 / 94

ERECTION OF STATIC EQUIPMENT

ITEM

LENGTH mm

WIDTH mm

THICK mm

SLOPE

Shim

100-450

50-200

3.2,4.5,9,12, 19,25

—

Wedge

100-450

50-200

6,9,12,16,19, 25 (max.)

4o-5o

6.3.0 6.3.1

6.3.2

6.3.3

6.3.4

INSTALLATION OF EQUIPMENT Inspection before installation 1. Prior to commencing the installation work, any damage during the transportation, the orientation of the equipment, the center of gravity, base level from the datum line of the foundation, the condition of the slings and lifting lugs, and the condition of the anchor bolts etc., shall be inspected thoroughly. 2. The function of brakes, clutches, other safety devices and controls of the winch shall be inspected. 3. To prevent overloading, any test water or other temporary materials remaining or left in the equipment shall be drained or removed. 4. The bottom face of the equipment base plate shall be cleaned. 5. The concrete surface of the foundation shall be thoroughly chipped and then be cleaned completely with compressed air, etc. 6. The required number of shims and wedges with the necessary tools shall be prepared to ready use. Precautions against storm 1. When the wind velocity exceeds 15m/sec. all installa tion work shall be stopped. 2. No equipment shall be installed under stormy winds, heavy rain or heavy snow. Special crew 1. During heavy equipment installation, especially installation by the gin pole/boom derrick a special crew shall be organized. 2. The crew shall comprises a general supervisor, signal/flag man, hoist operator, crane operator, rigger, safety supervisor, etc. 3. The function of each individual of the crew shall be clearly defined. Installation 1. Heavy equipment shall tentatively be lifted, slightly, to examine all parts of the gin pole/boom derrick, crane, wire ropes, tools, etc. If any defect is found, the equipment to be installed, shall be lowered on the ground. After the defect is corrected, the equipment shall be lifted slowly. 2. Crane work shall not be suspended at dangerous and incomplete positions during the lifting operation.

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION

PAGE 4 OF 5

3. The protective cover on equipment for nozzles and flanges shall not be removed without the approval of the Engineer-incharge. 4. During installation work, special care shall be taken so as not to damage the anchor bolts or their threads. 5. While seating and leveling, use shims and pairs of wedges. 6. As a rule, shims and wedges shall be placed on liner plates fixed on the concrete foundation at both sides of the anchor bolts, and leveling shall be done temporarily. Where the distance between anchor bolts is larger than 800mm, extra shims and wedges shall be located between the anchor bolts to prevent the base plate from bending. Wedges or shims shall not be substituted with wooden strips, bricks concrete blocks, etc. 7. After leveling is finished and all anchor bolts are firmly tightened, all shims and wedges to remain in place shall be tack-welded to prevent them from becoming loose. 8. As a rule, welded lifting lugs used in the installation shall be left in place.

7.0.0

ALIGNMENT

7.1.0 7.1.1

GENERAL All installed equipment shall be aligned plumbness or level. Towers/vertical vessels shall be aligned plumbness and satisfy the requirements of Par. 7.2.0 Horizontal vessels & heat exchangers shall be aligned level and satisfy the requirements of Par.7.3.0 PLUMBNESS 1. Plumbness shall be checked by viewing from two directions 90o apart with a transit. Check of plumbness of very tall equipment shall be done early in the morning. 2. Out-of-plumb of the equipment installed shall not exceed 1.0mm per lm of height or a total of 25mm for the entire height, whichever is smaller, unless otherwise specified in the job Specification. 3. After alignment is finished and the lock nuts of the anchor bolts are tightened firmly, the shims and wedges shall be tack-welded to each other and any excess in the shims and wedges shall be cut off with gas cutter. LEVELING 1. The alignment level shall be made using a spirit level instrument or a transit at four points based on the center line marked on the equipment in the shop. The level shall be aligned in the direction of AB or CD and AC or BD at the center line on the equipment. ( Refer to Fig. on Page 5 of 5 ) 2. The maximum tolerance shall be as shown in Table 3, unless otherwise specified.

7.1.2 7.1.3 7.2.0

7.3.0

TABLE - 3 POINT

25ES201 / 94

ERECTION OF STATIC EQUIPMENT A and B or C and D

l mm per Meter of Length

A and C or B and D

2 mm Max.

3. Considering the drain-out during maintenance, the channel end of the heat exchanger shall be lowered 1 to 2mm/m than the shell cover end. 4. After leveling is finished and the lock nuts of the anchor bolts are tightened firmly, the shims and wedges shall be tack-welded to each other and any excess in the shims and wedges shall be cut off with a gas cutter.

8.0.0

8.1.0

8.2.0

8.3.0

9.0.0

GROUTING Grouting shall be accomplished in accordance with the fol lowing requirements, unless otherwise specified. PREPARATION FOR GROUTING 1. The foundation surface shall be cleaned thoroughly and be removed of any dirt or oily spots. 2. The top surface of the foundation shall be wetted thoroughly with fresh water prior to grouting. MATERIAL 1. Portland cement mortar may be used in grouting under the base plates, unless otherwise specified. 2. The mixing ratio of portland cement and clean fine sand shall be approx. 1:2 in volume, and the ratio of water to cement shall be less than 40 percent in volume unless other wise specified. GROUTING PROCEDURE 1. The base plate shall be grouted as follows: a. The space under the base plate shall be packed full with grout. b. The grout shall cover all shims and wedges. 2. After the grouting mortar has been poured fully, the excess grout shall be trimmed away. The surface of the mortar outside of the base plate shall be finished smoothly. 3. The shims and wedges shall not be removed, unless otherwise specified.

LOOSENING SLIDE END ANCHOR BOLT 1. After grouting has set and hardened, the nuts of the sliding end anchor bolts shall be loosened to allow for thermal expansion. 2. The above requirement shall be applied to horizontal vessels, shell and tube heat exchangers, and when requested by the Engineer- in - charge

10.0.0 INSPECTION RECORD The results of the following inspections shall be recorded and submitted. 1. Alignment a. Plumbness b. Leveling

TOLERANCE

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION

ERECTION OF STATIC EQUIPMENT

25ES201 / 94 PAGE 5 OF 5

LEVELLING POINTS FOR HORIZONTAL EQUIPMENT

X A

B

C

D

X

PLAN

SCALE

A

C

B

D

VIEW X – X

LEVEL INSTRUMENT

FACT ENGINEERING AND DESIGN ORGANISATION 00FT001

iso2.sty

ENGINEERING SPECIFICATION

ERECTION-ALIGNMENT AND GROUTING OF MACHINERY ITEMS CONTENTS

1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 6.0.0

SCOPE INSPECTION AND STORAGE HANDLING ERECTION GROUTING ALIGNMENT

2.6.5 2.6.6 2.7.1 2.7.2

—————————————1.0.0 SCOPE 1.1.0

1.2.0

This specification covers the general requirements for the erection, alignment and grouting of machinery. For specific machineries, the requirements of the manufacturers installation manuals shall apply in addition to all non-conflicting requirements of this specification.

2.0.0

INSPECTION AND STORAGE

2.1.0

On receipt of machinery at site, it should be checked for completeness against the packing list and the purchase order specifications. Special care must be taken to see that the loosely packed items such as foundation bolts, couplings with bolts and nuts, belts, auxillary piping, all spares items including spares required during erection, special tools, coupling guard, hold down bolts, eye bolts, etc. have been supplied with the unit. The Engineer in charge shall also determine whether any damage has occured to the equipment during transit. The equipment with all the loosely packed items and spare parts shall be tagged and stored under covered storage place, to protect the equipment from weather and other forms of abuse. The tags on equipment shall indicate the following details: a. Equipment No. & Description. b. Plant and Location of Erection. c. P.O. Ref. d. Date of receipt & inspection at site. The equipments are to be stored separately plant wise to facilitate easy location and identification during erection. Should the equipment be not installed immediately after delivery, the closest adherence to the following in structions is strongly recommended. The base plate to rest fully on a flat surface and not just partially. The components not to be stacked one upon the other. All components and the equipment to be stored in a dry clean place. All machined parts, likely to corrode, either inside or outside, to be protected by suitable inhibitors (grease or rust preventive compound).

2.2.0

2.3.0

2.4.0

2.5.0 2.6.0

2.6.1 2.6.2 2.6.3 2.6.4

PRPD. BY:

CHKD. BY:

25ES202 / 94 PAGE 1 OF 3

All lids and covers to be closed to prevent dust or foreign matters from entering the equipment. Bearings and motors shall be kept in indoor installations. In rotating machinery, rotate the shaft weekly to coat the bearings and shaft surfaces with lubricant and to retard oxidation and corrosion. Some vendors may provide lock nuts to prevent the rotating parts from revolving during transit and handling. In such cases ensure appropriate coating method is done as per 2.6.4 above.

3.0.0

HANDLING

3.1.0

When handling the equipment, care must be taken to avoid supporting or lifting in a manner that would place excessive stress on parts or shaft extensions that are not designed to support the weight of the unit. Lifting hooks, Eyebolts, etc. if provided, should be used for lifting. Strings/wire ropes are to put through the portions of the equipment marked/recommended by the manufacturer of the equipment. All equipments are normally balanced at shop and sent to site. If the rotator shaft and rotator is damaged in anyway during handling it may cause an out of balance condition, which would require rebalancing or replacement of shaft.

3.2.0

4.0.0

ERECTION

4.1.0

Well before preparing for erection of the equipment ensure that the details of the equipment nozzle dimensions and locations, couplings, base plate, anchor bolts dimension and locations, direction of rotation of drive and driven units, details of key and key way as per the relevant drawings. Prepare an outline sketch of the equipment, which shall be used as ready reference sheet, marking the design requirements such as co-ordinates of the equipment centre lines, P.O.S. elevations, critical nozzle elevation, distance between shaft ends, minimum projection required for the anchor bolts from P.O.S. elevation, location and dimensions of anchor bolts, grouting clearance, etc. With the above details check the equipment and the respective foundation to take remedial actions for any discrepancy noted if it is beyond acceptable limits. The foundation block shall be made ready in advance, with regard to the date of erection of the equipment so as to permit the same suitably set. Before shifting the equipment to position the location of foundations, bolt holes, etc. shall be inspected the cross checked with the equipment to be erected. Any mistake noticed is to be rectified before erection. Before placing the equipment on the foundation roughen and clean the top of the foundation to remove oil, grease, dirt and any loose particles. Clean out care fully by compressed air hose the foundation bolt-holes. The top of the foundation shall be placed 25 to

4.2.0

4.3.0

4.4.0

4.5.0

4.6.0

4.7.0

APPRD. BY:

FACT ENGINEERING AND DESIGN ORGANISATION

ISSUED ON: MAR ’94

ENGINEERING SPECIFICATION

4.8.0 4.9.0 4.10.0 4.11.0

4.12.0

4.13.0

4.14.0 4.15.0

4.16.0

4.17.0

ERECTION-ALIGNMENT AND GROUTING OF MACHINERY ITEMS

50 mm below the final level of the equipment. Mark the centre-line of the equipment both on the foundation and on the equipment. Lift the equipment and place it on the foundation with the foundation bolts in position. Proper equipment and tools for lifting, leveling and alignment should be made ready before putting the machine over the foundation. The equipment shall rest on steel packing plates.Packing plates shall be placed very close to the foundation bolts and on either sides of all the foundation bolts. If the distance between anchor bolts are more than 800mm, additional packing plates shall be provided in between. Level and align the equipment base frame with utmost care using spirit levels or master level, depending on the precision required. High speed and high torque machinery shall be aligned with special care. The tolerances on alignment shall be maintained as per the installation manual furnished by the equipment suppli er. Note: Small equipments like centrifugal pumps etc. are aligned and assembled on the base frame at the shop. In these cases the equipments are directly erected on the foundation in the assembled form. The foundation surface will support the equipment with the packing plates under the base frame. The foundation should be smooth and level at these points to distribute the load evenly on the foundation through packing plates. A thin metal plate leveled in a puddle of grout is the easiest way to achieve this level and smooth surface. Always use thick shims wherever possible to avoid spongy shim base. Adjust shims under base plate until the base frame/equipment is level. The space between the base frame and foundation shall be 25 mm to 50 mm (or as per the instructions given in the manufacturer’s manual). For leveling the equipment use machined true surface viz. pump flange, coupling face, shaft surface, etc. After checking the level, the equipment is to be imme diately grouted - grouting shall be done as per 5.0.0

5.0.0

GROUTING

5.1.0

Grout compensates for unevenness in the foundation and base frame and distributes the weight of the unit uniformly over the foundation. It is preferable that the unit be expertly grouted with a non shrinking grout. Saturate with water the top surface of the foundation and the foundation bolt holes. Wetting with water should be done at least six hours prior to grouting. Remove excess water with air hose or rage before pouring grout. The grout mixture must be sufficiently fluid at the same time shrinkage must be minimum. Use a grout with lower water content and which can

5.2.0

5.3.0

5.4.0 5.5.0

5.6.0

5.7.0 5.8.0

5.9.0

25ES202 / 94 PAGE 2 OF 3

be operated easily on the narrow space under the base frame. The grout prepared must flow easily. Normal grouting mixture comprises of one part of port land cement and one part of clean fine sharp sand mixed in adequate quantity of water. To avoid shrinkage of grout during setting any non shrinking compound can be added to grout mixture as additive. During grouting of large base frames there is a possi bility of air trapping, which can be avoided by temporarily introducing thick walled rubber tubes to provide venting. Remove the tubes after the grout has filled all the cavities before pouring the remainder. The grout should be poured quickly and continuously to prevent unequal setting of grout. It is preferable to shut down other machines near the equipment which is being erected, as the vibration of running machineries will have damaging effect on the grouting and alignment of the new machine. The frame work for grout should be built to such a height that on setting the top of the grout is approximately 15mm above the bottom of the base plate.

6.0.0

ALIGNMENT

6.1.0

When the grouting is set, the holding down bolt should be gently but firmly tightened. Great care must be taken not to spring the bed plate by excessive tightening. Check the level again. Eventhough it is normal that small equipments will be aligned in the factory itself, it is mandatory that the unit be field aligned since any base plate can be warped in and when installed on foundation. The driven unit viz. pump, blower, compressor etc. is assembled and levelled on the base frame already grouted. Then the drive unit is bolted on the base frame, the clearance between couplings shall be set as per the manufacturers’ directive using feeler gauge and the unit be aligned. Preliminary coupling alignment may be done using straight edge and feeler gauge. The parallelism (angular alignment) and intersection of axes (shafts in line at the coupling ends) can be checked accurately using dial gauge. For using dial gauges it is essential that both driving and driven shafts rotate together. This can generally be accomplished by linking the couplings of the driving and driven units by at least one coupling pin. Alternatively where free movement between two half couplings are difficult the above alignment can be checked by rotating the half-drive coupling keeping the magnetic base of the dial gauge on the drive coupling, but the rim of the machine coupling should be marked at intervals of 90o and readings taken only when the mark are in line. Alignment is to be done using minimum dialgauges or with any suitable instruments available. Radial and axil alignment shall be checked simultaneously using two dial gauges.

6.2.0

6.3.0

6.4.0

6.5.0

6.6.0

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION 6.7.0

6.8.0 6.8.1

6.8.2

6.8.3

ERECTION-ALIGNMENT AND GROUTING OF MACHINERY ITEMS

TOLERANCES It is difficult to lay down limits of accuracy within which adjustments should be made because of the differences in the size and speed of units, but as a rough guidance, the following variations in the dial gauge readings can be tolerated. For angular alignment Couplings upto 12" dia : 0.002" Couplings over 12" dia : 0.003" For radial alignment readings more than 0.004" (i.e. 0.002" eccentricity) call for adjustment. The above figure are suggested for speeds upto 1500 rpm. For speeds of 3000 rpm or over a greater degree of accuracy should be observed. ALIGNMENT OF BELT DRIVE For belt driven equipment, the drive motors are generally mounted on independent slide rails. After final levelling and grouting of the driven equipment the slide rails are placed on steel shims over the motor foundation. The motor belts sheave is assembled on the motor shaft by using tapered bushing and cap screws. Do not lubricate the cap screws. The motor is placed on the slide rails nearer to the equipment side. The alignment of the driven unit sheave with the motor shaft sheave is checked by placing a straight edge or string across both sheave faces. Adjustments if any, may be done by moving the motor rails.

6.8.4 6.8.5 6.8.6 6.8.7

6.8.8

6.9.0 6.9.1

6.9.2

6.9.3

25ES202 / 94 PAGE 3 OF 3

The foundation bolts of the slide rails are grouted. The slides are also grouted after checking the levelling. After setting of foundation bolts grouting as well as side rails grouting, move the motor towards the driven unit as far as the slide base will permit. Install the belts in sheave grooves without forcing them. Do not pry the belts over the sheave rims with a screw driver or similar tool as this will damage the belts and greatly reduce belt service life. With the belts in the grooves, reposition the motor to take up the slack until the belts are fairly tight. BELT TENSION Start the drive motor, and continue to adjust the belt tension until the belts have only a slight ’bow’ in the slack side of the drive while operating underload. After a few days of operation, the belts will seat themselves in the sheave grooves and it may become necessary to readjust them so that the drive once again shows a slight “bow” in the slack side. The drive is now properly tensioned and should operate satisfactorily with only an occasional readjustment to compensate for normal belt and sheave groove wear.

—————————————————————-

FACT ENGINEERING AND DESIGN ORGANISATION

DATA SHEET

8122-01-DA FH100

FIRE HYDRANT SYSTEM

PAGE Applicable to : Site : Unit : 1.0 2.0 3.0 4.0 5.0 6.0 7.0

8.0 9.0 10.0 11.0

13.0

14.0

Purchase X Proposal MANGALORE LPG BLENDING FACILITY

Make Model Type No. off Codes / Standards Hydrant size Connection Type Size Dimensions Landing valve size Flow rate Pressure Material of construction Stand pipe Landing valve body Landing valve disc Accessories Coupling Blind cap with chain Certification

As built

1

TPS No. : 8122

mm

Single Hydrant 1 IS 5290 : 1993 Type A 63

mm lpm Kg/cm2G

Flanged 80 NB ANSI B16.5 150# 63 female instantaneous 900 7 operating / 15 design CS Gun mettal Gun mettal Instantaneous female required (brass) ISI marking

PROJECT CLIENT P.O No. 16.11.09 DATE

KK PRPD.

CRP CHKD.

JK APPRD.

1 1

Job No : Item No. : FIRE HYDRANT ASSEMBLY

Note: End connection of landing valve shall be 80 NB flange drilled to suit ANSI B 16.5

4 3 2 1 0 Rev

OF

LPG BLENDING FACILITY PLANT AT MANGALORE HPCL

VENDOR

FACT ENGINEERING AND DESIGN ORGANISATION

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

DATA SHEET

8122-01-DA FH103

FIRE HYDRANT SYSTEM

PAGE Applicable to : Site : Unit : 1.0 2.0 3.0 4.0 5.0 6.0 7.0

Purchase X Proposal MANGALORE LPG BLENDING FACILITY

Make Model Type No. off Codes / Standards Dimensions Capacity

8.0 Material of construction Thickness 9.0 Accessories Hose reels Couplings Keys Stand with foundation bolts 10.0 Hose station No. off Capacity

As built

1

OF

TPS No. :

Job No : Item No. : HOSE BOX

1 8122

Stand mounted type, glass fronted 1 mm

mm

30" x 10" x 24" (Height 24") To hold 1 no 15 M long hoses with branch pipes, nozzles & couplings MS galvanised and painted 20 guage

required required N/A

FACT ENGINEERING AND DESIGN ORGANISATION

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55

DATA SHEET

8122-01-DA FH102

FIRE HYDRANT SYSTEM

PAGE Applicable to : Site : Unit : 1.0 2.0 3.0 4.0 5.0 6.0

7.0 8.0 9.0 10.0 11.0

Purchase X Proposal MANGALORE LPG BLENDING FACILITY

Make Model Type No. off Codes / Standards Material of construction Spray nozzle Half coupling Flow rate K factor Orifice size Connection size Cone angle Acessories Spanner Half coupling

As built

1

OF

1 1

TPS No. :

Job No : Item No. : SPRAY NOZZLE

8122

Medium velocity spray nozzles - pendant type 11 FM / UL / NFPA Marine Bronze A 105 galvanized lpm mm Threaded Suitable for 15 mm, IS 554 deg. required required

Dimensional check and performance test shall be done on 10 % of nozzles selected at random

FACT ENGINEERING AND DESIGN ORGANISATION

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55

DATA SHEET

8122-01-DA-FH 104

FIRE HYDRANT SYSTEM

PAGE Applicable to : Site : Unit :

X Proposal

Purchase

LPG BLENDING FACILITY HPCL, MANGALORE

Make Model Type No. off Codes / Standards Valve size Connection Type Size Dimensions 10.0 Pressure 11.0 Material of construction Valve body Valve internals Valve disc 13.0 Accessories Isolation valves Bypass valve Pressure gauges Actuation piping Mating flages & pipe fittings Solinoid valve Pressure switch

01FT074C/94

1.0 2.0 3.0 4.0 5.0 6.0 7.0

4 3 2 1 0 Rev

20.11.09 DATE

kk PRPD.

crp CHKD.

As built

1

TPS No. :

1 1

Job No : Item No. : DELUGE VALVE SYSTEM

8122

2 mm

50

Kg/cm2G

Flanged 50NB As per B16.5, Class 150. FF 12 ALUMINIUM BRONZE Bronze Bronze ALUMINIUM BRONZE ALUMINIUM BRONZE

A105, galvanised, threaded

jk APPRD.

OF

PROJECT

LPG BLENDING FACILITY

CLIENT P.O No.

HPCL

VENDOR

FACT ENGINEERING AND DESIGN ORGANISATION

2 3 4 5 6 7 8 9 10 11 12 13 14 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

Page 1 of 6 ENGINEERING SPECIFICATION

8122-01-PS-002 DV Page 1 of 7

R0

STANDARD SPECIFICATION FOR

00FT021A/94

DELUGE VALVE

0

23.11.09

REV. NO.

DATE

First issue DESCRIPTION

KK

CRP

JK

PREPARED

CHECKED

APPROVED

FACT ENGINEERING AND DESIGN ORGANISATION

TECHNICAL PROCUREMENT SPECIFICATION

8112-01-PS-002 DV

SPECIAL REQUIREMENT OF THE PROJECT 2 of 7 R0

CONTENTS

1. SCOPE 2. CODES AND STANDARD 3. DESIGN REQUIREMENTS 4. MATERIAL OF CONSTRUCTION 5. CONSTRUCTION AND PERFORMANCE 6. INSPECTION AND MARKING 7. INFORMATION REQUIRED FROM VENDOR

ANNEXURE - 1

00FT021B/94

P&ID OF DELUGE VALVE (HYDRAULIC DETECTION SYSTEM)

FACT ENGINEERING AND DESIGN ORGANISATION

TECHNICAL PROCUREMENT SPECIFICATION

1.

8112-01-PS-002 DV

SPECIAL REQUIREMENT OF THE PROJECT 3 of 7 R0

SCOPE This specified describes design requirements, material of construction and performance of automatic deluge valve for fire water distribution.

2.0

CODES AND STANDARDS 1. 2. 3.

NEPA Codes Rules for Water Spray System (BY TAC) Indian Standard Specifications

3.0

DESIGN REQUIREMENTS

3.1

An automatic deluge valve shall consist of following: 1. 2. 3. 4. 5. 6. 7. 8.

3.2

Deluge valve unit Diaphragm unit Integral test and drain valve manifold Alarm system Priming equipment Installation stop valve with pressure gauge and outlet valve By pass ball valve Detector pipe work manifold

Size and capacity of deluge valve shall be as under: Size (Inch(mm)

00FT021B/94

2(50) 3(80) 4(100) 6(150) 8(200)

Rated Flow(lpm)

Working Pressure(kg/cm2g)

1150 5000 13500 18500

7.0 7.0 7.0 7.0 7.0

to to to to to

10.5 10.5 10.5 10.5 10.5

3.3

The deluge valve shall be provided with solenoid operated water release valve for remote operation in addition to automatic operation of deluge valve.

3.0

MATERIAL OF CONSTRUCTION

4.1

For non saline water service Body Seat Clack Diaphragm spindle and hinged pin Test and drain valve,

Cast iron to IS 210 Gr. FG 200 Bronze Graphite iron SS 304 )

FACT ENGINEERING AND DESIGN ORGANISATION

TECHNICAL PROCUREMENT SPECIFICATION

8112-01-PS-002 DV

SPECIAL REQUIREMENT OF THE PROJECT

Installation stop valve , ) Outlet valve and ) Check valve )

4 of 7 R0

Cast steel (A53A spec)

4.2

For saline water service aluminum bronze in place of cast iron and cast steel shall be used.

5.0

CONSTRUCTION AND PERFORMANCE

5.1

The deluge valve unit shall be provided with a clack to keep the valve close through a diaphragm unit.

5.2

The deluge valve shall also be fitted with an integral test and drain manifold. It shall consist of 50mm test and drain valve, body drain valve and a drip plug.

5.3

The test valve shall allow water to flow through the deluge valve to drain during testing of deluge valve and to drain water from distribution pipe after fire. At open position the valve clack shall be held against its seating by an internal compression spring of sufficient strength to keep it in closed position till the pressure acting on underside of it does not exceed approx. 0.3 kg/cm2. The clack will open at pressure exceeding 0.3 kg/cm2.

5.4

The drain valve shall drain all the water from the deluge valve body and the outlet connection during maintenance of the deluge valve. The drain pipe work is to be designed to periodically check the rate of flow available in the system to satisfy the requirements appropriate to the hazard class for which the deluge valve is provided. Flow measurement shall be checked with differential pressure. Water operated alarm motor gang shall be connected to the test and drain valve so that it gives an alarm as the deluge valve opens.

5.5

On detector pipe work manifold, test valve shall be provided at one end while on supply pipe pressure control regulator with by pass, isolation valve, check valve, strainer and restricted orifice shall be provided. Both detector pipe work and supply line shall be terminated with flanged ends. Piping shall be GI conforming to specification BIS. In case of hydraulic detector network, tapping from existing fire water network on U/S of deluge shall be taken by the vendor.

5.6

In addition to above an electric pressure switch shall be provided to give alarm at “Low pressure”. Low pressure alarm shall be set at 1.7kg/cm2. Provision of changing the set pressure of both the alarms shall also be provided.

00FT021B/94

The alarm switch(s) shall thus activate at low pressure of 1.7 kg/cm2 and with alarm to initiate warning of fire. Vendor shall confirm the set pressure based on inlet water supply pressure. For remote operation of the deluge valve, solenoid operated valve shall be provided.

FACT ENGINEERING AND DESIGN ORGANISATION

TECHNICAL PROCUREMENT SPECIFICATION

8112-01-PS-002 DV

SPECIAL REQUIREMENT OF THE PROJECT 5 of 7 R0

When deluge valve is located in an hazardous area, SOV and alarm switches shall be explosion proof/intrinsically safe and suitably for hazardous area. 5.7

Installation stop valve and outlet valve above deluge valve shall be as per piping specifications described above. In addition following provisions shall be made.

Valve must be strapped (not chained) end padlocked in open position a all normal times.

5.8

The deluge valve shall be tested for operation/opening at set pressure and operation of the alarms at set pressure.

5.9

For testing and setting of deluge valve a priming valve and a vent valve shall be provided with deluge valve assembly. At all normal times, and when testing the deluge valve according to various tests required, the body of the deluge valve shall remain full of water.

5.10

Pressure gauge shall be fitted immediately above the deluge valve on water supply line. Another pressure gauge shall be provided on detector pipe work manifold.

00FT021B/94

Pressure gauges shall be bourden type and shall be weather proof to NEMA-4. Vendor shall specify the range of pressure gauge and also submit detailed specification / data sheet of the instrument. 5.11

The complete valve assembly shall be of good workmanship and finish and free from burrs and sharp edges. All waterways shall have smooth finish.

5.12

The deluge valve shall be tested for a test pressure of 18kg/cm2g.

6.0

INSPECTION AND MARKING

6.1

HPCL or its authorised representatives shall have access at all reasonable times to the manufacturer’s work where the deluge valve assembly are being manufactured or being tested.

6.2

Deluge valve assembly shall be clearly and permanently marked with the purchaser’s name, design and test pressure.

7.0

INFORMATION REQUIRED FROM VENDOR

7.1

The vendor shall furnish the following information along with the offer and for approval prior to fabrication. -

P&ID of deluge valve General arrangement of deluge valve assembly and elevation Constructional features of deluge valve assembly Initial setting procedure of deluge valve Automatic and manual operational procedures

FACT ENGINEERING AND DESIGN ORGANISATION

TECHNICAL PROCUREMENT SPECIFICATION

00FT021B/94

-

8112-01-PS-002 DV

SPECIAL REQUIREMENT OF THE PROJECT 6 of 7 R0

Periodic testing and safety procedures

7.2

Following information shall be furnished by the vendor along with the supply of the deluge valve.

7.2.1

Instruction book(s) for the guidance of the user including both the operating and normal maintenance procedures. The book(s) shall include an itemized and illustrated part list / spare parts list giving reference no. of all the wearing parts.

7.2.2

Duly approved final drawings listed in Clause 7.1.

FACT ENGINEERING AND DESIGN ORGANISATION

FOR TENDER PURPOSE ONLY

FOR TENDER PURPOSE ONLY

FOR TENDER PURPOSE ONLY

FOR TENDER PURPOSE ONLY

FOR TENDER PURPOSE ONLY

FOR TENDER PURPOSE ONLY

FOR TENDER PURPOSE ONLY

FOR TENDER PURPOSE ONLY

FOR TENDER PURPOSE ONLY

FOR TENDER PURPOSE ONLY

INSULATION

FOR TENDER PURPOSE ONLY FLOW SHEET REF. REF DRAWINGS

NOTES

FACT ENGINEERING & DESIGN ORGANISATION

INSULATION

FOR TENDER PURPOSE ONLY FLOW SHEET REF. REF DRAWINGS

NOTES

FACT ENGINEERING & DESIGN ORGANISATION

INSULATION

FOR TENDER PURPOSE ONLY FLOW SHEET REF. REF DRAWINGS

NOTES

FACT ENGINEERING & DESIGN ORGANISATION

INSULATION

FOR TENDER PURPOSE ONLY FLOW SHEET REF. REF DRAWINGS

NOTES

FACT ENGINEERING & DESIGN ORGANISATION

INSULATION

FOR TENDER PURPOSE ONLY FLOW SHEET REF. REF DRAWINGS

NOTES

FACT ENGINEERING & DESIGN ORGANISATION

INSULATION

FOR TENDER PURPOSE ONLY FLOW SHEET REF. REF DRAWINGS

NOTES

FACT ENGINEERING & DESIGN ORGANISATION

INSULATION

FOR TENDER PURPOSE ONLY FLOW SHEET REF. REF DRAWINGS

NOTES

FACT ENGINEERING & DESIGN ORGANISATION

INSULATION

FOR TENDER PURPOSE ONLY FLOW SHEET REF. REF DRAWINGS

NOTES

FACT ENGINEERING & DESIGN ORGANISATION

INSULATION

FOR TENDER PURPOSE ONLY FLOW SHEET REF. REF DRAWINGS

NOTES

FACT ENGINEERING & DESIGN ORGANISATION

INSULATION

FOR TENDER PURPOSE ONLY FLOW SHEET REF. REF DRAWINGS

NOTES

FACT ENGINEERING & DESIGN ORGANISATION

INSULATION

FOR TENDER PURPOSE ONLY FLOW SHEET REF. REF DRAWINGS

NOTES

FACT ENGINEERING & DESIGN ORGANISATION

INSULATION

FOR TENDER PURPOSE ONLY FLOW SHEET REF. REF DRAWINGS

NOTES

FACT ENGINEERING & DESIGN ORGANISATION

INSULATION

FOR TENDER PURPOSE ONLY FLOW SHEET REF. REF DRAWINGS

NOTES

FACT ENGINEERING & DESIGN ORGANISATION

INSULATION

FOR TENDER PURPOSE ONLY FLOW SHEET REF. REF DRAWINGS

NOTES

FACT ENGINEERING & DESIGN ORGANISATION

INSULATION

FOR TENDER PURPOSE ONLY FLOW SHEET REF. REF DRAWINGS

NOTES

FACT ENGINEERING & DESIGN ORGANISATION

INSULATION

FOR TENDER PURPOSE ONLY FLOW SHEET REF. REF DRAWINGS

NOTES

FACT ENGINEERING & DESIGN ORGANISATION

PIPING DEPARTMENT Sl. No. (1) A

SCHEDULE OF ITEMS OF WORK Description of item (2)

Unit (3)

Quantity (4)

8122 - 03 - SW - 001 PAGE 1 OF 10 R 0 Rate Rs. (5) Amount Rs. Fig. Words (6)

FABRICATION AND INSTALLATION OF PIPING

The scope of work under this item includes transportation of all piping items from storage point, handling, cleaning, welding, fabrication, erection, painting, testing and commissioning of above ground piping as per the drawings and specifications. All activities associated with making weld joints such as cleaning, marking out, cutting , profiling, bevelling, grinding, aligning, fitting up, tack welding, chipping, preheating, placing of wind shields/weather protection and final welding together with any special wlelding requirement are included in the scope. Installation of all types of valves, control valves, safety valves, Y strainers, static mixure, orifice plates and assembling of flanged joints are also included in the rate. The contractor shall ensure the initial satisfactory operation of the valves. Cleaning of flange faces, insertion of gaskets, bolts etc, aligning and tightening of bolts etc are included. Making of threaded nipples from pipe is also included All the works required for the proper installation, at all elevations, of piping with attached fittings and valves, handling, rigging, scaffolding, placing and alignment of pipes and fittings to their respective positions and on to their respective supports, fabrication and erection of trunnion supports, pad at supports are also included in this item. Hydraulic testing of the piping systems, flushing, draining and drying up also included in this.

03FT067B/ 96

All the CS pipes, fittings etc shall be painted with 1 coat of 'Two pack poly urethane holding primer’ as per 02ES023/97 after surface cleaning by mechanical means The pay quantity shall be the actual centreline length in metres of straight or fabricated pipe including valves, etc. actually installed as required. Payment for the work done will be made only when the piping is properly located and permanently supported in its final position in the field after hydrotesting. This rate does not cover radiography/UT/MP/DP tests,which shall be paid as per item D PrepAred - GSP Project - LPG Blending facilities

Checked - KAK

FACT ENGINEERING AND DESIGN ORGANISATION

Approved - KAK

15.10.09

PIPING DEPARTMENT Sl. No. (1) A.1

SCHEDULE OF ITEMS OF WORK Description of item (2)

Unit (3)

Quantity (4)

M

2

CARBON STEEL, ASTM A 106 GR B

1

20NB

SCH160

2

25 NB

SCH 80

6

3

40NB

SCH 80

2

4

50 NB

SCH 40

6

5

100 NB

SCH 40

6

6

250 NB

SCH 40

6

7

300 NB

SCH 40

235

A.2

LOW TEMP CARBON STEEL, ASTM A333 GR 1 / Gr 6

1

20NB

SCH160

2

40NB

SCH 80

2

3

150NB

SCH 40

12

4

200 NB

SCH 40

200

5

250 NB

SCH 40

200

6

300 NB

SCH 40

24

A.3

Fig.

8122-03-SW-001 PAGE 2 OF 10 R0 Rate Rs. (5) Amount Rs. Words (6)

M

2

GLASS REINFORCED PLASTIC ( GRP) AS PER SPECIFICATION

1

25 NB

PN 10

M

1

2

40 NB

PN 10

1

3

50 NB

PN 10

2

4

100 NB

PN 10

1

5

150 NB

PN 10

18

6

200 NB

PN 10

3

7

250NB

PN 10

3 Total / Sub-total

FACT ENGINEERING AND DESIGN ORGANISATION

PIPING DEPARTMENT Sl. No. (1) A.3

SCHEDULE OF ITEMS OF WORK Description of item (2)

Unit (3)

Quantity (4)

GLASS REINFORCED PLASTIC ( GRP) AS PER SPECIFICATION

C/O

8

300 NB

PN 10

9

400NB

PN 10

194

10

450 NB

PN 10

1

11

500 NB

PN 10

1

A.4

Fig.

8122-03-SW-001 PAGE 3 OF 10 R0 Rate Rs. (5) Amount Rs. Words (6)

M

3

CEMENT LINED PIPING The rate shall also include making Tie in connections, galvanised fasteners, non metallic gaskets, sleeves, sand, cement, reinforcement etc

1

100 NB

2

300NB

5

3

450NB

35

B

M

5

SUPPLY AND APPLICATION OF COLD INSULATION Supply and application of Pre formed PUF cold Insulation, over pipes, valves, flanges, specials as per specifications/standards/drawings and instruction from the site in charge. 12 mm concrete coating shall be provided over the insulation. All the materials, tools/tackles, scaffolding, transportation/handling, manpower etc. shall be arranged by the contractor. Measurements for the release of payment shall be as per IS 14164.

1

20NB

60 MM THICK

M

4

2

25NB

60 MM THICK

9

3

40NB

60 MM THICK

4

4

50NB

60 MM THICK

6

5

100NB

60 MM THICK

6 Total / Sub-total

FACT ENGINEERING AND DESIGN ORGANISATION

PIPING DEPARTMENT Sl. No. (1) B

SCHEDULE OF ITEMS OF WORK Description of item (2)

Unit (3)

Quantity (4)

SUPPLY AND APPLICATION OF COLD INSULATION

C/O

6

150NB

60 MM THICK

7

150NB

90 MM THICK

6

8

200NB

90 MM THICK

195

9

250NB

60 MM THICK

195

10

300NB

60 MM THICK

250

C

M

12

TIE IN CONNECTIONS All activities required for taking two tappings from the existing header at Terminal and shall include all safety precautions such as draining/ flushing/ blinding etc, cutting the header, providing flanged MOV in the line , welding two equal tees in the pipeline oneither side of the MOV etc

D

Fig.

8122-03-SW-001 PAGE 4 OF 10 R0 Rate Rs. (5) Amount Rs. Words (6)

LS

1

RADIOGRAPHY / DYE PENETRANT TESTS. Radiographic, UT/ DP / MP inspection of the weld joints shall be conducted as per the code, specs., drgs. and instructions of the Engineer-in-charge. The rate quoted shall be inclusive of all operations necessary to fulfill the work of radiography ( X ray / Gamma ray ), DP / MP tests including all tools / tackles, films, chemicals etc. complete. After testing, if any joint is found defective, the same shall be rectified and re-tested free of cost. The pay quantity shall be linear centimeters of weld successfully passed. Penalty shots shall not be counted for payment.

1

Radiographic/ UltrasonicInspection

CMS

27000

2

DP Inspection

CMS

700 Total / Sub-total

FACT ENGINEERING AND DESIGN ORGANISATION

PIPING DEPARTMENT Sl. No. (1)

SCHEDULE OF ITEMS OF WORK Unit (3)

Description of item (2)

E

DISMANTLING OF PIPING

1

Cutting and dismantling of pipelines including attached fittings, flanges, valves, instruments, insulation etc, transporting to owner's store or other designated areas without damage to nearby equipments, pipelines, structures etc in a safe and sound manner. Cement lined piping 100NB

Quantity (4)

C/O

M

5

2

300NB

5

3

450NB

35

150NB

6

5

250NB

6

6

300NB

6

4

Carbon Steel piping

Fig.

8122-03-SW-001 PAGE 5 OF 10 R0 Rate Rs. (5) Amount Rs. Words (6)

F

MISCELLANEOUS JOBS

1

Fabrication, erection and Painting of structural supports Supply, transportation, handling, rigging, cutting, edge preparation, drilling, threading, welding and fixing of structural supports at all elevations and chipping and grouting and clamping/ bolting/ fixing of pipelines (including cost of sand & cement for grouting). MS Plates & structurals shall be included in the rate

MT

2.5

The structural supports shall be painted with 1 coat of ‘Two pack poly urethane holding primer’ ( 30 microns DFT) and final painting shall be 2 coats of ‘High build poly urethane coating’ ( 60 microns total DFT). 2

PCC/ RCC pedestals for pipe supports including cost of materials

Cu M

5

3

Chipping of RCC for fixing insert plates, clamps, making cut outs etc

Cu M

2

4

Erection of Basket Filters Nos

2

Erection of flanged basket filter, 400NB, 150#, on the foundation, levelling, grouting , anchoring, fixing of accessories such as vent/drain valves, davit assembly, pressure guages etc, initial servicing .

Total / Sub-total

FACT ENGINEERING AND DESIGN ORGANISATION

PIPING DEPARTMENT Sl. No. (1)

Description of item (2)

Unit (3)

Quantity (4)

GRP PIPES, PN 10

C/O

1

25NB

2

40NB

1

3

50NB

2

4

100NB

1

5

150NB

18

6

200NB

3

7

250NB

3

8

300NB

3

9

400NB

194

10

450NB

1

11

500NB

1

G.2

Fig.

8122-03-SW-001 PAGE 6 OF 10 R0 Rate Rs. (5) Amount Rs. Words (6)

SUPPLY OF GLASS REINFORCED PLASTIC (GRP) ITEMS AS PER SPECIFICATION

G G.1

SCHEDULE OF ITEMS OF WORK

M

1

GRP FLANGES, 150#, FF, DRILLING AS PER B16.5

1

25NB

NOS

16

2

40NB

2

3

50NB

1

4

100NB

4

5

150NB

8

6

200NB

2

7

250NB

3 Total / Sub-total

FACT ENGINEERING AND DESIGN ORGANISATION

PIPING DEPARTMENT Sl. No. (1) G.3

SCHEDULE OF ITEMS OF WORK Description of item (2)

Unit (3)

Quantity (4)

Fig.

GRP FLANGES, 150#, FF, DRILLING AS PER B16.5

8122-03-SW-001 PAGE 7 OF 10 R0 Rate Rs. (5) Amount Rs. Words (6) C/O

1

300NB

NOS

18

2

400NB

22

3

450NB

1

4

500NB

1

5 G.4

GRP BLIND FLANGES, 150#, FF, DRILLING AS PER B16.5

1

40 NB

2

400 NB

G.5

NOS

2 1

90 DEG ELBOW, GRP, PN 10

1

50NB

2

100NB

3

3

150NB

14

4

200NB

3

5

250NB

3

6

400NB

15

G.6

NOS

1

45 DEG ELBOW, GRP, PN 10

1

400NB

NOS

3

1

150NB

NOS

1

2

400NB

G.7

EQUAL TEE, GRP, PN 10

2 Total / Sub-total

FACT ENGINEERING AND DESIGN ORGANISATION

PIPING DEPARTMENT Sl. No. (1)

SCHEDULE OF ITEMS OF WORK Description of item (2)

Unit (3)

Quantity (4)

Fig.

8122-03-SW-001 PAGE 8 OF 10 R0 Rate Rs. (5) Amount Rs. Words (6) C/O

G.8

CONCENTRIC REDUCER , GRP, PN 10 500NB X 400NB

NOS

1

1

450NB X 400NB

NOS

1

2

300NB X 250NB

1 G.9

G.10

1

G.11

ECCENTRIC REDUCER , GRP, PN 10

3

GATE VALVES - LEADED TIN BRONZE BODY AS PER IS 318 LTB2 AND TRIM AS PER IS 320 ALLOY HT2. ENDS SHALL BE FLANGED AS PER CLASS 150, B 16.5, FF. DESIGN PR - 10 BAR, TEMP - 50 DEG C. 25NB

RUBBER EXPANSION BELLOWS SUITABLE FOR SEA WATER PUMP DISCHARGE LINE . OPERATING PRESSURE - 10 BAR. FLANGED AS PER B16.5, FF, CLASS 150. SIZE - 300NB. OVERALL LENGTH 400MM.

NOS

11

NOS

3

Total / Sub-total

FACT ENGINEERING AND DESIGN ORGANISATION

PIPING DEPARTMENT Sl. No. (1)

SCHEDULE OF ITEMS OF WORK Description of item (2)

Quantity (4)

GI PIPES AS PER IS 1239, HEAVY, THREADED ENDS

C/O

1

25NB

2

40NB

43

3

50NB

50

4

80NB

1

5

100NB

30

H.2 H.3

Fig.

SUPPLY & INSTALLATION OF OF GALVANISED (GI) ITEMS

H H.1

Unit (3)

8122-03-SW-001 PAGE 9 OF 10 R0 Rate Rs. (5) Amount Rs. Words (6)

GI FLANGES, A105, 150#, FF, DRILLING AS PER B16.5, THREADED - 100NB GI FITTINGS, A105, CLASS 3000, THREADED

M

40

NOS

1

NOS

4

1

90 ELBOW

25 NB

2

90 ELBOW

40 NB

7

3

90 ELBOW

50 NB

4

4

EQUAL TEE

25 NB

3

5

EQUAL TEE

40 NB

1

6

EQUAL TEE

50 NB

1

7

UNEQUAL TEE

40 NB x 25 NB

1

8

UNEQUAL TEE

40 NB x 15 NB

8

9

UNEQUAL TEE

25 NB x 15 NB

14

10

CON. REDUCER

40 NB x 25 NB

3

11

CON. REDUCER

50 NB x 40 NB

2

12

COUPLING

25 NB

7

13

COUPLING

40 NB

10 Total / Sub-total

FACT ENGINEERING AND DESIGN ORGANISATION

PIPING DEPARTMENT Sl. No. (1)

I I.1 I.2 I.3

SCHEDULE OF ITEMS OF WORK Description of item (2)

Unit (3)

Quantity (4)

Fig.

8122-03-SW-001 PAGE 10 OF 10 R0 Rate Rs. (5) Amount Rs. Words (6)

SUPPLY & INSTALLATION OF FIRE FIGHTING ITEMS INCLUDING GASKETS AND FASTENERS SH FIRE HYDRANT AS PER IS 8442 & DATA SHEET, STAND POST TYPE 1, SIZE 63MM WATER MONITIRS AS PER IS 5290:1993 & DATA SHEET SIZE 32MM SPRAY NOZZLES AS PER IS 319 TYPE II & DATA SHEET, SIZE K40

NOS

1

NOS

1

NOS

11

I.4

QUARTZOID BULB, 15 MM, MALE THREADED

NOS

11

I.5

CI GATE VALVE AS PER IS 14846, PN 1.0 WITH BRONZE INTERNALS. FLANGED AS PER B16.5 , 150# , FF, 100NB

NOS

1

I.6

DELUGE VALVE ASSEMBLY CONSISTING OF DELUGE VALVE, 2 NOS ISOLATION VALVES, BYPASS VALVE, CONNECTED PIPING, GASKETS, FASTENERS AND MATING FLANGES AS PER DATA SHEET& ENGG SPEC. SIZE 50NB

NOS

2

I.7

HOSE BOX AS PER DATA SHEET

NOS

1

C/O

INSTALLATION OF EQUIPMENTS

J J.1

P301A/B- LPG BOOSTER PUMPS- VERTICAL- 4 TE APPR

J.2

P401A/B/C- SEA WATER PUMPS- VERTICAL- 2.75 TE APPR

3

J.3

JOCKEY PUMP- VERTICAL- 1TE APPR

2

J.4

E301- LPG HEATER- HORIZONTAL

NOS

TE

2

10.5

DISMANTLING OF PUMPS

K K.1

JOCKEY PUMP- VERTICAL- 1 TE APPR

NOS

2

K.2

WATER INJECTION PUMP- VERTICAL- 1.5 TE APPR

NOS

1 Total / Sub-total

FACT ENGINEERING AND DESIGN ORGANISATION

PIPING DEPARTMENT Sl. No. (1) A

SCHEDULE OF ITEMS OF WORK Unit (3)

Description of item (2)

Quantity (4)

FABRICATION AND INSTALLATION OF PIPING

The scope of work under this item includes transportation of all piping items from storage point, handling, cleaning, welding, fabrication, erection, painting, testing and commissioning of above ground piping as per the drawings and specifications. All activities associated with making weld joints such as cleaning, marking out, cutting , profiling, bevelling, grinding, aligning, fitting up, tack welding, chipping, preheating, placing of wind shields/weather protection and final welding together with any special wlelding requirement are included in the scope. Installation of all types of valves, control valves, safety valves, Y strainers, static mixure, orifice plates and assembling of flanged joints are also included in the rate. The contractor shall ensure the initial satisfactory operation of the valves. Cleaning of flange faces, insertion of gaskets, bolts etc, aligning and tightening of bolts etc are included. Making of threaded nipples from pipe is also included All the works required for the proper installation, at all elevations, of piping with attached fittings and valves, handling, rigging, scaffolding, placing and alignment of pipes and fittings to their respective positions and on to their respective supports, fabrication and erection of trunnion supports, pad at supports are also included in this item. Hydraulic testing of the piping systems, flushing, draining and drying up also included in this. All the CS pipes, fittings etc shall be painted with 1 coat of 'Two pack poly urethane holding primer’ as per 02ES023/97 after surface cleaning by mechanical means

03FT067B/ 96

The pay quantity shall be the actual centreline length in metres of straight or fabricated pipe including valves, etc. actually installed as required. Payment for the work done will be made only when the piping is properly located and permanently supported in its final position in the field after hydrotesting. This rate does not cover radiography/UT/MP/DP tests,which shall be paid as per item D PrepAred - GSP Project - LPG Blending facilities

Checked - KAK

FACT ENGINEERING AND DESIGN ORGANISATION

Approved - KAK

PIPING DEPARTMENT Sl. No. (1)

SCHEDULE OF ITEMS OF WORK Description of item (2)

Unit (3)

Quantity (4)

M

2

CARBON STEEL, ASTM A 106 GR B 2

20NB

SCH160

3

25 NB

SCH 80

6

4

40NB

SCH 80

2

5

50 NB

SCH 40

6

6

100 NB

SCH 40

6

7

250 NB

SCH 40

6

8

300 NB

SCH 40

235

LOW TEMP CARBON STEEL, ASTM A333 GR 1 / Gr 6 9

20NB

SCH160

M

2

10

40NB

SCH 80

2

11

150NB

SCH 40

12

12

200 NB

SCH 40

200

13

250 NB

SCH 40

200

14

300 NB

SCH 40

24

GLASS REINFORCED PLASTIC ( GRP) AS PER SPECIFICATION 15

25 NB

PN 10

M

16

40 NB

PN 10

1

17

50 NB

PN 10

2

18

100 NB

PN 10

1

19

150 NB

PN 10

18

20

200 NB

PN 10

3

21

250NB

PN 10

3

FACT ENGINEERING AND DESIGN ORGANISATION

1

PIPING DEPARTMENT Sl. No. (1)

SCHEDULE OF ITEMS OF WORK Description of item (2)

Unit (3)

Quantity (4)

M

3

GLASS REINFORCED PLASTIC ( GRP) AS PER SPECIFICATION 22

300 NB

PN 10

23

400NB

PN 10

194

24

450 NB

PN 10

1

25

500 NB

PN 10

1

CEMENT LINED PIPING The rate shall also include making Tie in connections, galvanised fasteners, non metallic gaskets, sleeves, sand, cement, reinforcement etc 26

100 NB

M

5

27

300NB

5

28

450NB

35

SUPPLY AND APPLICATION OF COLD INSULATION Supply and application of Pre formed PUF cold Insulation, over pipes, valves, flanges, specials as per specifications/standards/drawings and instruction from the site in charge. 12 mm concrete coating shall be provided over the insulation. All the materials, tools/tackles, scaffolding, transportation/handling, manpower etc. shall be arranged by the contractor. Measurements for the release of payment shall be as per IS 14164. 29

20NB

60 MM THICK

M

30

25NB

60 MM THICK

9

31

40NB

60 MM THICK

4

32

50NB

60 MM THICK

6

33

100NB

60 MM THICK

6

FACT ENGINEERING AND DESIGN ORGANISATION

4

PIPING DEPARTMENT Sl. No. (1)

SCHEDULE OF ITEMS OF WORK Description of item (2)

Unit (3)

Quantity (4)

M

12

SUPPLY AND APPLICATION OF COLD INSULATION 34

150NB

60 MM THICK

35

150NB

90 MM THICK

6

36

200NB

90 MM THICK

195

37

250NB

60 MM THICK

195

38

300NB

60 MM THICK

250

39

TIE IN CONNECTIONS All activities required for taking two tappings from the existing header at Terminal and shall include all safety precautions such as draining/ flushing/ blinding etc, cutting the header, providing flanged MOV in the line , welding two equal tees in the pipeline oneither side of the MOV etc

LS

1

RADIOGRAPHY / DYE PENETRANT TESTS. Radiographic, UT/ DP / MP inspection of the weld joints shall be conducted as per the code, specs., drgs. and instructions of the Engineer-in-charge. The rate quoted shall be inclusive of all operations necessary to fulfill the work of radiography ( X ray / Gamma ray ), DP / MP tests including all tools / tackles, films, chemicals etc. complete. After testing, if any joint is found defective, the same shall be rectified and re-tested free of cost. The pay quantity shall be linear centimeters of weld successfully passed. Penalty shots shall not be counted for payment. 40

Radiographic/ UltrasonicInspection

CM

27000

41

DP Inspection

CM

700

FACT ENGINEERING AND DESIGN ORGANISATION

PIPING DEPARTMENT Sl. No. (1)

SCHEDULE OF ITEMS OF WORK Description of item (2)

Unit (3)

Quantity (4)

M

5

DISMANTLING OF PIPING

42

Cutting and dismantling of pipelines including attached fittings, flanges, valves, instruments, insulation etc, transporting to owner's store or other designated areas without damage to nearby equipments, pipelines, structures etc in a safe and sound manner. Cement lined piping 100NB

43

300NB

5

44

450NB

35

150NB

6

46

250NB

6

47

300NB

6

45

Carbon Steel piping

MISCELLANEOUS JOBS 48

Fabrication, erection and Painting of structural supports Supply, transportation, handling, rigging, cutting, edge preparation, drilling, threading, welding and fixing of structural supports at all elevations and chipping and grouting and clamping/ bolting/ fixing of pipelines (including cost of sand & cement for grouting). MS Plates & structurals shall be included in the rate

TM

2.5

The structural supports shall be painted with 1 coat of ‘Two pack poly urethane holding primer’ ( 30 microns DFT) and final painting shall be 2 coats of ‘High build poly urethane coating’ ( 60 microns total DFT). 49

PCC/ RCC pedestals for pipe supports including cost of materials

Cu M

5

50

Chipping of RCC for fixing insert plates, clamps, making cut outs etc

Cu M

2

51

Erection of Basket Filters Nos

2

Erection of flanged basket filter, 400NB, 150#, on the foundation, levelling, grouting , anchoring, fixing of accessories such as vent/drain valves, davit assembly, pressure guages etc, initial servicing .

FACT ENGINEERING AND DESIGN ORGANISATION

PIPING DEPARTMENT Sl. No. (1)

SCHEDULE OF ITEMS OF WORK Description of item (2)

R0 Unit (3)

Quantity (4)

SUPPLY OF GLASS REINFORCED PLASTIC (GRP) ITEMS AS PER SPECIFICATION GRP PIPES, PN 10 52

25NB

M

1

53

40NB

1

54

50NB

2

55

100NB

1

56

150NB

18

57

200NB

3

58

250NB

3

59

300NB

3

60

400NB

194

61

450NB

1

62

500NB

1

GRP FLANGES, 150#, FF, DRILLING AS PER B16.5 63

25NB

NOS

64

40NB

2

65

50NB

1

66

100NB

4

67

150NB

8

68

200NB

2

69

250NB

3

FACT ENGINEERING AND DESIGN ORGANISATION

16

PIPING DEPARTMENT Sl. No. (1)

SCHEDULE OF ITEMS OF WORK Description of item (2)

Unit (3)

Quantity (4)

NOS

18

GRP FLANGES, 150#, FF, DRILLING AS PER B16.5 70

300NB

71

400NB

22

72

450NB

1

73

500NB

1

GRP BLIND FLANGES, 150#, FF, DRILLING AS PER B16.5 74

40 NB

75

400 NB

NOS

2 1

90 DEG ELBOW, GRP, PN 10 76

50NB

NOS

1

77

100NB

3

78

150NB

14

79

200NB

3

80

250NB

3

81

400NB

15

45 DEG ELBOW, GRP, PN 10 82

400NB

NOS

3

83

150NB

NOS

1

84

400NB

EQUAL TEE, GRP, PN 10

FACT ENGINEERING AND DESIGN ORGANISATION

2

FACT ENGINEERING AND DESIGN ORGANISATION

PIPING DEPARTMENT Sl. No. (1)

SCHEDULE OF ITEMS OF WORK Description of item (2)

Unit (3)

Quantity (4)

500NB X 400NB

NOS

1

86

450NB X 400NB

NOS

1

87

300NB X 250NB

CONCENTRIC REDUCER , GRP, PN 10 85 ECCENTRIC REDUCER , GRP, PN 10

3

GATE VALVES - LEADED TIN BRONZE BODY AS PER IS 318 LTB2 AND TRIM AS PER IS 320 ALLOY HT2. ENDS SHALL BE FLANGED AS PER CLASS 150, B 16.5, FF. DESIGN PR - 10 BAR, TEMP - 50 DEG C. 25NB

88

89

RUBBER EXPANSION BELLOWS 300NB

NOS

11

NOS

3

FACT ENGINEERING AND DESIGN ORGANISATION

PIPING DEPARTMENT Sl. No. (1)

SCHEDULE OF ITEMS OF WORK Description of item (2)

Unit (3)

R0 Quantity (4)

SUPPLY & INSTALLATION OF OF GALVANISED (GI) ITEMS GI PIPES AS PER IS 1239, HEAVY, THREADED ENDS 90

25NB

M

40

91

40NB

43

92

50NB

50

93

80NB

1

94

100NB

30

GI FLANGES, 150#, FF, DRILLING AS PER B16.5, THREADED 95

100NB

NOS

1

NOS

4

GI FITTINGS, A105, CLASS 3000, THREADED 96

90 ELBOW

25 NB

97

90 ELBOW

40 NB

7

98

90 ELBOW

50 NB

4

99

EQUAL TEE

25 NB

3

100

EQUAL TEE

40 NB

1

101

EQUAL TEE

50 NB

1

102

UNEQUAL TEE

40 NB x 25 NB

1

103

UNEQUAL TEE

40 NB x 15 NB

8

104

UNEQUAL TEE

25 NB x 15 NB

14

105

CON. REDUCER

40 NB x 25 NB

3

106

CON. REDUCER

50 NB x 40 NB

2

107

COUPLING

25 NB

7

108

COUPLING

40 NB

10

FACT ENGINEERING AND DESIGN ORGANISATION

PIPING DEPARTMENT Sl. No. (1)

SCHEDULE OF ITEMS OF WORK Description of item (2)

R0 Unit (3)

Quantity (4)

SUPPLY & INSTALLATION OF FIRE FIGHTING ITEMS 109 110

111

SH FIRE HYDRANT AS PER IS 8442 & DATA SHEET, STAND POST TYPE 1, SIZE 63MM WATER MONITIRS AS PER IS 5290:1993 & DATA SHEET SIZE 32MM

SPRAY NOZZLES AS IS 319 TYPE II & DATA SHEET, SIZE K40

NOS

1

NOS

1

NOS

11

112

QUARTZOID BULB, 15 MM, MALE THREADED

NOS

11

113

CI GATE VALVE AS PER IS 14846, PN 1.0 WITH BRONZE INTERNALS. FLANGED AS PER B16.5 , 150# , FF 100NB

NOS

1

114

DELUGE VALVE ASSEMBLY

NOS

2

115

HOSE BOX AS PER DATA SHEET

NOS

1

NOS

2

INSTALLATION OF EQUIPMENTS 116

P301A/B- LPG BOOSTER PUMPS- VERTICAL- 4 TE APPR

117

P401A/B/C- SEA WATER PUMPS- VERTICAL- 2.75 TE APPR

3

118

JOCKEY PUMP- VERTICAL- 1TE APPR

2

119

E301- LPG HEATER- HORIZONTAL

TM

10.5

DISMANTLING OF PUMPS 120

JOCKEY PUMP- VERTICAL- 1 TE APPR

NOS

2

121

WATER INJECTION PUMP- VERTICAL- 1.5 TE APPR

NOS

1

FACT ENGINEERING AND DESIGN ORGANISATION